Hi Norm,

It kind of sounds like the wires were mixed up going to the rec/reg ,the 2 wires from the stator ,one wire goes to the rec/reg for battery DC charging and the other wire from the stator is an AC current that goes to power the headlights and remains AC.

Sounds like you needed the one wire rec/reg.

Cheers
Max.

Attachments
alternator_replacement.pdf (2).png (58 KB, 30 downloads)
alternator_replacement.pdf (3).png (21.94 KB, 30 downloads)
Engine swap - alternator query.png (130.14 KB, 30 downloads)