Battery Problems after Rebuild

For those who have to know how the saga ends...

I met the Powermaster Rep at Goodguys and he gave me good advice:

1. Remove the voltage regulator on the back of the alternator and take it to the local parts house and tell'em it's off a 65 Mustang.
-the alternator is good.

2. Lacking any better plan, I replace the voltage regulator (30 bucks) that bolts onto the alternator
-still dies afer 24 hours of running.

3. I take the 1 year old battery back to the store, plead my case, and the manager feels sorry for me and replaces my battery and throws in pair of felt terminal washers (woo hoo!).
-dies next day

4. I test the battery hot and cold- no change in voltage

5. I check for voltage drop accross the battery landscape - AH HA!
I had installed a battery circuit disconnect (the one with the green knob) at the positive terminal - I had a serious voltage drop from the disconect post to the cable leading to the starter relay.

I threw out the disconnect device, cleaned the contacts with my $1.99 terminal cleaner, and I think my problem is solved.

I drive the car for a few days and had no problems.
In summary, I believe I had:
a) excessive resistance across the the disconnect device
b) marginal battery- could overcome the resistance issues when fully charged
c) loose belt after the rebuild - that prevented the batttery from being maximally charged after a day of driving

Thanks for all the input! This forum is the greatest!

Marc in SF
63 Comet
70 C4/250I6
http://mercurycomet.net
 
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