I faced a similar dilemma last fall. After a high RPM jaunt, my generator just quit charging. I couldn't figure out what the problem was. The generator had maybe 10,000 miles on it since being rebuilt, and the regulator was only a few years old. I tested the generator and it tested ok. So I replaced the regulator with one from Rock Auto. Still no dice. At that point I said screw it - why put more time and money into an old 30 amp generator setup (that never worked at idle) when I could swap in an 80 amp 12SI alternator. I think I probably have less than $200 into the whole conversion, and it works a helluva lot better too.
