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nice mount mod. question for us that do not have ability to machine this nicely.... what about just cutting across the bottom with sawzall then use grinder to compete the mod. Essentualy just removing the area in the red rectangle and grind small notch to final align hole in the alt's rear...

minimum Alternator with 200amp output at 24v if your heavy battery usage like a camper, that gets battery charging for Start/drive and house banks. Or off road w/heavy electric winching. Otherwise shrink start/drive to two batts and 100amp 24v will get-er-done

IMHO if your in a boat to have to fork out huge sums of money... Dump the Neihoff and spend the money on getting a domestic commericial 24v alternator and a 24v to12v convertor to run the 12v stuff. There is some threads in here on this idea. Also Jerrit sells a mount kit... can also get kit...

Check to see if the excite wire is telling the alternator to set abut to do it's thing. Think its 24v. Comes from the Oil pressure switch on the engine. This has been a common issue with A0's. That wire is known to Fubar itself. A few folk have found the Oil Pressure switch to be no longer...

Does your alternator regulator have LED's. Usually it is newer ones... but sometimes you get lucky and the regulator has LED's indicators that flash based on whats going on

well you got that pretty covered. Now guess measure the outputs at alternator and follow the path down from there at any spot you can to see if it drops anywhere? hmm. now think about it.... how is your ground from alt. to chassis? Maybe clean that up good?

what is battery voltage(s) Clean the terminals on the Rev. Polarity Box.