p.j.,
Sorry to hear about the ongoing problems. When you say 'fried the armature', do you mean it actually threw solder? If the band was on the generator, this would have 'shrapnel' blown all over it.
I have little knowledge of these generators, but everything I read says this is a sure sign the unit is producing tons of heat from excessive output.
I agree with you...the new regulator should have solved this problem, and throwing in a fresh battery really should have done it. If your ammeter never shows a massive charge, I wonder if the guilty party could another sticking cutout relay. I think this would start cooking the generator as it tried to 'motor' it, but would probably show itself as a dead for dying battery.
It seems that any wiring issue that put the generator into full output and subsequent failure would be apparent on your ammeter.
Did the springs in the brush holders seem plenty strong..these weren't changed while the armature was.
Stuart
