I have an InterAv alternator conversion that has been giving me troubles off and on over the years. It’ll go months with nary a twitch in the ammeter, then it’ll discharge at inopportune moments. Today it was in icing with the electrics loaded up. Every time it happens, I find one connection on the voltage regulator that is loose and allows the wires to move, but someone replaced the screw with one that was not oem and it will not tighten adequately. I have put on washers to no avail. Do you think I’m right to suspect the regulator or should I be looking at the alternator. When I tighten the suspect connection, the system charges right away, after a few hours, it doesn’t want to charge under 1300 rpm. If I do replace, go with plane power regulator? Thanks!

I can't speak to the components being good or bad, but If I had frequent loosening of wire connections that were suspected linked to problems I'd run a machine screw through the wire end fastener and component's threaded tang and install a self locking nut underneath. Washers can be used to insure a full contact. Screws and lock washers will loosen but a screw and locking nut are there forever until the wire fatigues and separates from the typically crimped on end. Installing heat shrink tubing over that end connection can support it and reduce fatigue.

Gary