hi artben- your picture of the armature and this message were very instructive. two questions for you on charging engineering realities: the slots on the armature end show one notch clearly ripped up.surely this would damage the brushes each time they pass the rotating mass. can that be repaired? smoothing the rough spot with some fine emory paper would appear useful, but you really cant level the notch so it is precisely in line with the others. this would lead to nicking the brush on each pass. with that problem seems the only fix would be a rebuilt alternator swap. am i right? also like the idea of a dash voltmeter. think you can still get small round stewart warner or other good dash meters which could mount neatly in one of those push in covers next to the radio in my 92 245. recall there are 2 wires one ground and one hot to attach. where would be the best connection points for the gauge? btw if i ever see you in a tobacco road ravine at 2 am in sc, md with smoke pouring from under the hood of your 240 i will stop and render assistance so you can rest easy. thanks tons oldduke