overcharging

I can check that in the morning.

Going to make up a ground with star washers for the VR off of one of the fasteners as well.

not excited about the thought of sanding anything down to bare metal on a 4 year old paint job.

Bruce
That sounds good. I hear you on the sanding!
You can check for voltage drop between the regulator body and other ground points like battery negative or the engine block. If there's difference in voltage between two ground where current is flowing then there's resistance.
Do your visual checks first. Definately want to minimize the time the system is running above 15 Volts.