Thanks for the input guys. I reckon a 75 amp alternator should do the trick. There's one available from a Mitsubishi Diamante, which should fit. Yes, all my circuits, even my Hella air horns are wired across relays, so the original Volvo wiring are just triggers. Anyone know what is the output of a later model 240, and if it is a direct fit?

My only concern now is the slight dimming of the headlamps when the A/C kicks on, or when they dim in unison when I got my Ozzy playing full blast...

Oh yes, one more thing, a 75 244 electronic ignition is in the works, don't think that it will sap too much power though.
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...and the bricks keep on rolling