Charging woes

As bad as they are I find this hard to believe. The voltage is set by a zener diode in the VR. Most of the time they either work or they dont. Could be a poor ground, AKA the mounting bolts, or even corrosion/ looseness in the connector. Perhaps you pulled and re-installed the connector so many times (LOL) you finally scrubbed the terminals clean.

I often recommend that folks pull and push connectors to "feel" for tightness and to scrub the terminals.
Cleaning the connectors is the first thing I did. Even ran a ground from the regulator to the engine ground point. All contacts cleaned and dielectric greased. Even ran through all the voltage regulators again to confirm. They all gave high values except for one