I'm no expert, but it seems like we're chasing our tails on this one - really shouldn't be this hard.
Cap'n, has your mechanic hooked up an ammeter (like a Sun VAT unit) at the generator and compared its reading to the dash unit during the observed deep discharge event? That would show whether or not this is an instrumentation problem.
Also, test your ground connections for the generator and regulator to make sure that any shiny new paint isn't causing a problem. If ground isn't found where "expected", electricity will try to find it some other way - and funny things can happen. IIRC, you have the full diagram on the AEA chart.
Speaking of ground, you wrote:
Quote:
He jumped from the 'hot' (positive) wire on the generator directly to the positive terminal on the battery....The problem instantly corrected itself.
Are you trying to say that your mechanic jumpered the generator's ground (G) terminal directly to the battery's ground (+) terminal and solved the problem. That would indicate a deficient ground for the generator.
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