Hi Kim,
Been following your progress. Sounds like an adveture in spite of the 'Lucas Factor'.
I know you said that your generator is new (last year) so maybe this is moot ~ or just too obvious.
Are the brushes contacting the armature properly?
It sounds like such an inane question & I'm sure someone must have mentioned it.
Just thought I'd ask. Reason is, I had to drive my Mini Cooper 300 miles under the same electrical conditons you describe & that was the problem.
Regards, Graham