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-Edit-
Looks like I already gave you all this info a while back. Still, it stands investigating what I've suggested. At least let us know
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This was likely mentioned long ago, but have you replaced your Voltage regulator and confirmed that you have the right type for your alternator (Bosch vs. SEV)?
The problems you describe remind me of my first and only non-volvo car - a 1978 Datsun F10 Coupe(Crap). I went through batteries and two alternators before I figured out that the voltage regulator (also replaced) was not grounded properly. As soon as I got it cleaned and bolted back on, my amp light vanished and I never had that problem again. I had *plenty* of other problems with that car...
Back in 1997, my 72 145 had some charging issues which turned out to be worn brushes in the alternator itself. My mechanic (at the time) made me some new ones for me as they were no longer available (aparrently this is very easy as brushes are jusy chunks of graphite with little springs on them). The Bosch unit that I salvaged from a 75 245 also had a charging problem that I believe was due to degraded windings. It already had new brushes (NOS from eBay) and bad winding was the remaining possibility. I ended up buying a *new* 1975-compatible replacement on eBay for $80.00 and have not had a problem since.
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