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Scott, much of what that regulator does is dependant upon it having its own good ground you know. I think Id run a good ground wire direct from the grounded batery post to its case n see how she acts then. If the VR's relay contacts need some tweaking like a gap thickness or spring tension that can be a lil tricky to describe over the net but being there n armed with the right equipment n specs it wouldnt be so bad. For now Id just double check all the wires n connections n ESPECIALLY the VR's ground n maybe as non abrasively as possible try more of that clean/buff/polish up the relay contact points cuz its not working that bad it dont sound like. Id still suspicion the condition of the set of relay contacts you already had to sand cuz once the shiny silvery coating is off they can be resistive n it dont take much to make them stop working correct. Check the VR ground,,,,,clean/buff/polish the relay contacts,,,,, ,maybe use some contact cleaner on them once done,,,,, maybe tweak the adjustments just a tad,,,,,make sure the belts good n tight and the battery is okay n all connections n just run her a while n see if she settles in to her milk. If dead grounding the gennys FLD post makes her charge well but she dont otherwise, sounds like you still have a VR problem or a bad VR ground if none of the above helps. You might wanna clean up the gennys commutator n check the brushes n hold down springys, it dont sound like the third brush needs adjusted but it might not hurt to bump it up to a lil higher charge rate if its not already maxxed out John T
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