I tried replacing voltage regulator, did not fix the problem.
I went ahead and took it apart and found evidence that the stator and rotor had been coming on contact with each other. Also found a loose/broken solder joint on one of the stator wires to the diode carrier plate. Dropped the alt off with a local auto electric guy who rebuilds such things to see if he can source a new stator and/or fix what I've got.
Shoot your in raleigh i just noticed, i can check i may have a 65 amp from a cabriolet i parted. Your welcome to it if you want it you'd likely have to monkey with housing halves or pulleys to use it diesel style but its just sitting in my garage gathering dust. at the least you may be able to pirate some internals off it. I'm in apex green level church and green level west.
The OP wolfsburged had his off the car and tested it failed dc out, that wouldn't be the exciter wire. Unless i'm missing something? I know the exciter wire is a pia and the source of a ton of issues but in this case it doesn't sound practical.
Not the exciter wire, I did check that, and it failed off the car at two different shops (just to make sure they were testing it correctly). Should have a new one in today with any luck.