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It was the inner coil connection that failed. Unwound the coil to discover. Since the wire is not damaged, it is being reused.

I've measured the coil from slip rings to where the magnet wire goes into the coil, open circuit and no short to poles. What had happened to the alternator was a regulator failure and high voltage 14.8+. Full rotor voltage meant uncontrolled current, overheating the rotor. The drive belt was...

The autozone DL7157 rebuilt I got is a genuine Delco core. It won't be a waste of time for me to rewind it, nothing special. Just pull the claw pole off the rotor at the drive end, desolder or braze the slip ring connections and the spool should slide off. I can get the wire for $10 a pound...

I went to the local rebuilder, they only had series 200 type 27SI rotors. But at $128, the Autozone alternator was cheaper and right now. It LOOKS rebuildable, the drive end claw pole is pressed onto the shaft over splines, there are two holes which could be tapped to hold that pole piece...

It finally hit me, an alternator that a repair kit couldn't fix. Since I couldn't find a replacement rotor and the vehicle is a daily driver for the youngest son, I broke down and bought an autozone non isolated ground. It I'd for the left side position, working fine now. looking over the...