Excess resistance between the alternator and the VR would have no effect on starting. Slow down and review from the begining. You're missing a lot that has already been dealt with.
Please do not talk down to me. I'm an NOT talking about "excess resistance" between the alternator OUTPUT and the battery which does NOT cause the VR to overcharge.
I am talking about YOUR suggested tests which IF there is harness voltage drop in the VR IGN circuit WILL cause overvoltage but is VERY UNLIKELY to cause this much over voltage.
The kind of overcharge the OP is experiencing is most likely a serious problem in the field circuit. Could even be something like wires melted together in the harness causing the VR to effectively be "out of the circuit"
