Good deal on the key switch!

Does it have the standard pulleys all around? Check the new alternator pulley and make sure it is not larger than the stock pulley; if so, that would slow down the alternator and higher revs would be needed for full output. Re-tighten the fan belt a bit too and see if that helps.

And what actual rev's are required for 'full output' and how are you checking for 'full output'? It typically won't put out full charge 'til around 1500 engine rpm. But even then, if you are using the ammeter to judge charging and the battery is well charged to start with, then with everything off (like headlights) the ammeter will not show charging until higher RPM's. With a full charge, the battery simply won't accept any more charge at moderate alternator speeds.

You are better off checking the voltage at the battery versus RPM's with a voltmeter to judge this.

nm9stheham - Same pulley size, and fan belt is tight (no slipping on the belt at all).

When the car wouldn't start I called a road side assistance, he charged the battery with a pack and allowed me to start the car (essentially a jump start).

He used a volt meter to test the output and said what's coming from the alternator even at WOT seems to not be much, and at idle no charge was going into the battery.

He also had one of those electric field things over the neg battery wire, (think they measure current?).

Hopefully in the coming weeks I'll grab some wire and aligator clips to isolate the charging circuit to see if I can diagnose the problem like that.

The starter motor sounds like it's on the way out - seems to kick in with the crunching sound near instantly at the turn of the key, and requires some co ordinate pedal pumping and key turning for the car to start - perhaps a rebuild is req, and this may be where I am having a power problem? - I say this because the positive cable connects to part of the starter motor (and a few other cables as well).

Cheers

Just one random experience with belts: I have had one brand (Dayco Top Cog) that has the belt notches in the outer surface that gavae trouble. I had 2 that were tight as a drum and would still slip when running, with no noise or smell. Drove me nuts on both cars where this happened. So a new belt would be a good idea, IMO.

Yes, it was probably a clip-on ammeter on the neg battery lead.

The starter may be going bad but that is not at all likely to have any effect on charging; the starter is completely out of the circuit expect when starting.