12v Palm Beach Buggy 351 Windsor Alternator and voltage regulator issues

[PWJouster]

We have a swamp buggy thats been giving us overcharging issues. Dual battery setup-Blue tops, Napa/autozone standard Voltage regulator, and an old timer re manufactured Mastercraft 1g alternator.

idle is near 12+- volts and with RPM we peak on the meter at 16, but at the alternator we are putting out 17+.
it has fried a battery and swelled another.
brand new batteries and VR, no dice.
new Ground strap on VR and Alternator, no dice
New alternator, No dice
Rewire, No dice

We are going to attempt a one wire alternator with built in VR, but we arent sure what will happen.




We are eating up batteries and replacing voltage regulators to no avail.
anyone have any tips on overcharge issues?
Only a few LEDs and no sound, could power be under utilized? What about throwing on halogenlights and a fridge?

[Retired BLM Rig]

Check all your grounds. A corrupt ground path can mask true system voltage resulting in a overcharge condition. A voltage drop test will isolate where the bad connection is.

[PWJouster]

We ran new grounds from the regulator to frame and from alternator case to frame.

Do we need to ground the VR to the Alt?
Does the Alt need a direct ground?
Engine block ground is on the opposite side and back side of the block to the frame rails, Which was an box chevy I think?
Can too many redundant grounds cause fielding issues if the grounds are carrying different resistance?

[PWJouster]

Ordered a new multi meter to assist with this, for redundancy.

[Retired BLM Rig]

Doing a voltage drop test on both the power and ground side should isolate the problem for you.