Good lord that's certainly unpleasant. Lucky the battery responded to a refill.

It sounds to me like possibly the small red wire is grounding out somewhere in the harness or under the car or next to the alternator on that foil hose?

If it were to ground out, the unit may try to charge excessively.

You said a rebuilt was just installed- have a close look at all the alternator connections, and make sure the red wire is intact next to and below/inboard of the alternator where the harness goes through the bracket behind the pulley. Also inspect the blue ground wire at this time- make sure the 8mm nut is tight on the alternator body, and the 12mm bolt to the engine block is good right below the alt bracket.

Good luck with it!
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