Hi Mike,
Nice to hear about others that share the same goal. Interesting to find out that newer alternators apparently now do include a regulator with the required higher setpoint voltage . Seems manufacturers are finally cleaning up their act, and less batteries will end up prematurely in the landfills.
My alternator is a S-Class 115-Amp model, I believe made specifically for the 93-94 model car. Maybe I'll give the parts guy a call and ask him what the set voltage of the replacement regulators are. Mine clearly has written "14.1V" on it, so hopefully it will be easy to determine the spec of any other Bosch regulator currently available over the counter.
It seems most of the aftermarket 14.5V voltage regulators out there are junk made in china, so I'm not too surprised that yours had a fitting problem. Nowadays one can't even trust the familiar yellow Bosch box, even if it states "Made in Germany". It seems the chinese are counterfeiting everything. Just the other day I purchased a couple of common Bosch horn relays (the black cube ones with the mounting flange), and they turned out to be all cheap stuff inside, even tough they where individually packed in nice original looking Made in Germany" boxes. I compared the insides to a known original relay, and there was a BIG difference in quality and workmanship.
BTW, there is a parts catalog of Bosch alternator parts in PDF format that is pretty good for visual references:
http://site.amscovf.com/boschalternatorparts.pdf