Happy to report some progress this weekend. I didn't meet my own goals of having her back driving but much was accomplished.

Charging issue: Boy. I had a hell of a time with this alternator. If I could swear in German...

I need to look up the alternator threads and re-read see if I missed something- I probably did.

Issue 1: You must use the factory metal fan and NOT the one provided with the Bosch unit. The Bosch fan is just a few mm larger and ends up fouling on the alternator bracket.

Issue 2: This was noted in one of the alternator threads, but I foolishly dismissed it. The posts onto which you put the eye ring terminals on the Bosch unit are actually WAY longer than they need to be. It doesn't seem like this would make ANY difference, but it actually makes the alternator essentially impossible to put into position. Solution is to simply cut/grind off the excess. I lopped off about 1/4" from the main terminal and maybe 1/6th" from the smaller.

Issue 3: Not really a huge issue but the wiring I used for the signal wire on the alternator (the blue wire) is an absurdly small gauge - maybe 18 or 20 AWG - I used a 10 or 12 AWG wire because that's what I had handy. In retrospect I could and should have just used some standard hook up wire. My signal wire is way overkill and just created an annoyance when connecting it to the blue wire.

Other than that, the bolts are such a pia to access. I think I need to invest in some ratcheting wrenches. Unbolting and tightening those bolts 1/4" of a turn at a time ends up taking forever.

But all the issues aside, I have wired what I believe to be a superior job to the factory while keeping mostly factory locations for the wiring. The alternator is charging at idle 14.2 volts. So right as rain there.

And the real good news - all three of my permanent warning lights (Battery light, brake light and brake wear light) have now gone off!

In addition the tachometer is working again now that I've replaced the fuse. Huzzah.

Leak issue:

While I was working on the alternator, I decided since the battery was undone I should remove it and the battery tray and inspect for rust holes behind it.

Well, I found one. Where the hood hinges evidently drain to below the battery tray and into the fender was a bit clogged. There was also a rust hole developing right next to it in the corner. I cleaned it up as best I could and really dug at it to see if it went through.

I hooked up lights from the interior and exterior and checked both ways to see if light was penetrating into the cabin. However, none was. So this might be a source of some of the leaking. It's hard to say.

Regardless, after cleaning up the area I attempted to degrease it as best I could and then applied a POR-15 like substance the affected area. Used my heat gun set to low and had the area nice and warmed up before application and during drying. Gave the affected area two coats and let dry. I then applied 3M seam sealer to the area also in two steps building up the hole and surrounding area so that water will go directly to the drain.

Who knows if that will help... but can't hurt!