Re: alternator output question
Before you go through all that, have you upgraded any of your stock wires (known as the big 3, the ground from the batt to the firewall or where ever its grounded at, the line going from the alt to the battery, and the one going to the ground on the block)? if not, you may have lots of corrison on the stock parts. Try cleaning the stockers up/ making new ones out of 4awg cable(unless you have a big system, in that case bump up to 0/1 awg). This should help some, and if this IS whats causing the problem, moving to a bigger alt with the stock pully isn't going to help one bit.
If that doesn't clear it up, you can swap on the stock pullie and test the voltage with a simple DMM to see. You'll be looking for 13.8v (at least) at anything above idle, and at least 12.6v at idle as most alternators suck at idle no matter what they are rated for. Also, with some the larger alternators, you'll be eating up 7-8 hp to turn them I belive.