I offered this arrangement with diagrams and alternator recommendations to ORC when we first talked about it a year ago, and I still haven't gotten a reply...
This is a great set up!
Your dying coil problem is a bad engine ground, 9 chances out of 10...
This should solve it.
Usually, an good, direct engine ground, using star washers in the connections will solve the coil roasting problem once and for all.
The only thing I would have done differently was to use brass bolts in your terminal strips.
With dissimilar metals, and current, you are going to have corrosion in the joints, no matter what.
Love that Teflon idea to isolate that positive buss bar!! You just solved a problem I was working on!
You should consider building a jig, and selling that battery tie down tray and solenoid mounting arrangement.
If you decide to, let me know, and I'll help with suppliers.
Maybe add another product....?....
Great execution of the details!! The devil is always in the details, and you left no area untouched!!
Good cable, great connections, and great design!!!
If you are ever in the southern Indiana area, I may have you stop in and show me a thing or two!!
CJ Dave and I are both going to get wet over that ground buss!
You can never preach enough about grounding everything that has power!
Use some star washers between the connections, and you have saved yourself a TON of electrical problems!!
As far as your alternator goes, Leece-Neville makes one for school busses and big trucks.
Isolated ground, so you actually have a ground connection on the back of the alternator (you can use it on positive ground vehicles too), and it throws between 130 and 160 CONTINUOUS duty output amps. (not just peak amps, like most smaller alts are rated)
The regulator is good enough that they put it on computer controlled vehicles, and it doesn't amp or volt spike too much...
I've seen them in the wholesale catalogs for under $100 outright, with no core charge, but over the counter they normally want about $300...
Let me know if you are interested, and I'll send pictures and particulars...
Let me know exactly what you want me to do, and I'll try and help, but my time is very limited right now...
If it's a get to it when I get to it project, I'll do what ever I can.
Send it to me on email, and I'm more likely to get it....
"I Have The Body Of A God... Buddha"