[crainholio]

I just made progress toward solving the crappy rebuilt alternator mystery up here in NNJ. I blew a NAPA rebuild after only 2-3 sessions at Pocono road course and got spooked after reading that chain store rebuilt LS1 alts seems to have this problem large scale.

I took the warranty replacement alt to a mom 'n pop auto electric shop, they found 40-Amp diodes in the crappy Chinese rectifier. Delco spec is 50-Amp diodes. No wonder the thing popped so quickly. Soon as you spin the thing to max output you're nearly at the limit of the diodes' capacity...3 diodes on the positive side, 3 on the negative side, that's 120-amp capacity on each w/ the crappy rectifier.

They're installing a heavy duty rectifier with 70-amp diodes for like $70 out the door.

I'd dig through the phone book under Automobile Generator/Starter/Alternator or whatever and find an established rebuild shop. You'll spend less $$ and get a better alternator.