I have a 1980 Rabbit Convertible with the stock 1.6L and no A/C. I would like to replace the 55 Amp spade-terminal alternator with a 65A or 90A alternator with post-type terminals, so that I can run a nice fat 4 gauge wire directly to the battery + cable, and so that I can run seat heaters and an amp without fear. Are there any 65A or 90A alternators with post terminals that would be a direct fit? I'm actually happy with the V-belt setup and don't want to switch to serpentine. Maybe something for a later Cabriolet w/o A/C would work?
Also, the current alternator has been burning alternator wires. I replaced the main wires with two direct 10 gauge copper cables to the battery + terminal, and used a brand-new Lucas-type alternator plug. After having some charging issues on a recent road trip (alternator has only ever charged at 12.5V, and was dropping down to 10V at points on the journey), I pulled the alternator and noticed that the area around the terminal, including the newish connector, was all burnt again. What is that about? Is it just a crappy alternator?
I've had horrible alternator luck with this car. After the original died at 150K, the replacements have only lasted about 10K miles each. The first was charging at 18V even after I changed the voltage regulator; the second charged fine but then ate a bearing and seized in the desert; and the third is the current one, which has always been subpar.
And yes, I am replacing the battery (-) cable and main ground wires.