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Hello Stick,
Couple of things to check, you may already have. Have you checked the voltage output and current after the car warms up? I had an alternator once on a non Volvo ride that worked like a champ when you first started the car up. However after the car warmed up the voltage started dropping until the battery was actually doing all the work. Resulted in a dead battery every few days until a new alternator was installed. The alternator when it was warmed up did fail the current load test on the Auto Zone tester. Passed the same test when the the car was barely warmed up.
Have you checked the ground wire from the alternator frame to the engine block is solid? It gets eaten up by corrosion and the amount of current the alternator can deliver depends on that connection to the engine block.
Just a thought and good luck. Looking for a gremlin in the August heat is no fun.
Regards,
Paul
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