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And a final question...I was unable to trace this connection on any of the diagrams...can someone identify this?

Ok, we have success. Good news, the charging system is back up to 14.4 volts. After a third attempt at rooting through wires, cleaning grounds and replacing fusible links I located what I think was the issue. Or at least a combination of electrical snafu's that made the issue. Attached is a...

Load tested both batteries this morning. They are in good shape, no bad cells. Hmmm. Back to the drawing board. There is a ground strap from the firewall to a bolt on the top, back of the passenger side engine block. A braided wire deal. It looks like **** and is frayed. I'll replace that...

Replaced both relays under the dash next to the starter relay - the exciter and the voltage meter. They both had lots of corrosion. Cleaned the connections, di-electric grease and bolted back up. Still 12.3 volts and dropping...placed charger on for the night. Will revisit in the morning...

Ok, the test results. Key off: Red = 12.8, brown = 0 Key on: Red = 11.8, brown = 11.4 Should I replace the exciter relay?

Warthog - yes the alternator is a civy unit. The Ultima from OReilly's, the one that would go into the 1975 cadillac, heavy duty and isolated. It is grounded as indicated in the Rosscommon directions. I still have the original passenger side alternator. It was missing the drivers side one...

Ok, so far I have checked and recheck the wiring from the Passenger side Alternator and beyond. I have even labeled the wires with my wifes handy label maker. Several wires have been be replaced with all new connections and some the whole wire is new as specified in the schematics. Still...

Copy that, I am on it! Pretty confident of the job, but you're right - it's worth a second and third check!

You may be right sir, it is dark and rainy here, but a quick test found that with headlights on, the voltage at the batteries was 12...11.9 I will check again in the morning to verify. Both batteries are not very old, just a year. If just one cell is bad would that bring the whole system done?

Yes, but that is normal. The sense wire is the brown correct? And a reminder, this is a 12 volt conversion vehicle. Runs and sounds good, Rosscommon followed and double checked. aua

Will do, I read one of your earlier threads about the Rosscommon conversion not charging. More info - All new bulbs and cleaned instrument cluster. Dielectric grease, shiny brass on the connections. A 194 bulb is on Gen 2. It lights up with a turn of the key, WAIT light on, then off, she...

Ok, I'll be to the point. Like many here, I put a lot of time and research into this obsession. Just when you think it is all ready... I am only getting 12.4 volts at the batteries while engine running. Removed and had the Alternator tested (lifetime warranty from OReilly). Watched the...