Alternator and Voltage Regulator Questions

If you knew all this why are you askin us?

1...Seriously, though "parts store" test benches leave a lot to be desired. You CAN NOT really test an alternator without a full load and big enough motor to drive it to full load. The 1/4hp motor used on a typical test bench "ain't it"

VR might be a different matter, but that doesn't mean the parts store tester is "correct."

2....So far as your battery vs alternator stud test, this basically does not tell you much because it is not tested under load. There can be considerable resistance in the "charge path" from the alternator to the battery and you will get that reading WITH NO CURRENT going through that path

3....As I mentioned before TEST IT ON THE CAR. If you do this correctly there will be little reason to doubt your findings. I have no idea, at this point.......why you got smoke from the harness........ You didn't say if or what you found. THIS MIGHT MEAN there is still an intermittent short and the "smoke" might return.

4....YOU ARE NOT DONE YET!!!! You (the rest of us do/ did) likely have voltage drop in the ignition harness which will caust the VR to run over-voltage. Get the car warmed up and run long enough to get the battery "normalized." Check voltage at the battery running fast enough RPM to keep the alternator activated. If you read much over 14.2, you need to check the following:

5....To check for harness drop, Turn the key to "run" with the engine stopped. Hook your meter to the closest point you can get (electrically) to the VR IGN terminal, and the other lead to battery PLUS

What you are hoping for is a VERY low reading, the lower the better. Anything over about .3V (3/10 of one volt) you need to look into why

Also be CERTAIN the VR is grounded properly with the mount, and that you have a proper jumper from the firewall/ VR or at least the front fender / rad support to the battery NEG. I like to add a no4 "starter" cable (eye to eye cable) from the rear of the drivers side head to the firewall, such as the master cylinder stud mount