A few more thoughts now that I'm awake:
* the tensioner spring likely can't be flipped... the ones that I have had apart aren't internally symmetrical
* hit the junkyard for a longer/shorter tensioner arm -- they are fairly standard with respect to pivot bolt and anti-pivot diameter, and there are many applications which <img src="/forums/images/graemlins/evil.gif" alt="" /> swing both ways <img src="/forums/images/graemlins/evil.gif" alt="" />
* you may be able to redrill the tensioner seat anti-pivot bore
* most tensioners have a built-in indicator which shows the range of useful motion -- look for a few stamped tickmarks in the face
* pulley sizes vary the driven speed of the accessories -- twiddle
with care and this can work in your favor for belt alignment and wrap and/or idle and top speed limits on accessories
If it helps, neither the alternator nor the idler care which way they spin -- but the power steering pump, water pump, and likely the AC compressor (if you use it for more than an idler) are unhappy being spun in reverse. With a little searching, I'd be surprised if counter-rotating variants were not available, or couldn't be made to fit with custom brackets.
Erm... I made up a term. <img src="/forums/images/graemlins/pfft.gif" alt="" /> 'Anti-pivot' is the cast-in 'pin' on the backside of the tensioner and the corresponding bore on the surface to which it mounts. When these are engaged, they provide the resistance for the spring inside the tensioner, and the whole shebang pivots around the center bolt. Clear as mud?
Does the stock non-AC accessory dress run an extra idler wheel or just different brackets?
Seems like rotating the alternator 30 degrees counter-clockwise around its left- and lower-most anchor point might pull it into the useful range of the tensioner. Look at this pic but rotate the alternator the other way around the other hole:
http://berisford.net/uploads/cpom/projectpup/6/12.jpgOne parting bit of advice -- figure out what belts are available before you spend too much time figuring out how you want the belt to route. BTDT, and had to change my plans based on belt availability. Since you are likely running a standard, single-sided serpentine belt, this may not be much of a limiter for you.
Keep working on it -- I respect your continued work, and am all-to-aware of the second law of momentum: objects at rest tend to remain at rest...
Randii