Smaller pulley sounds plausible - more revolutions per turn = increase output. Has anybody done this? Where to get smaller pulley? I'll look into this too.

Also, when I installed the higher output alternator, instructions said to bypass the voltage regulator altogether. I called customer support and sure nuf, guy says not to connect volt. reg. I did this and this is where I stand now. Is this normal? Weird that I would have a voltage regulator sitting under the hood not connected to alt. I'm seriously thinking about doing the brushes on stock and putting it back in. Thanks for the inputs.