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Ok, So regardless of my previous short, there IS something wrong with my generator. Its chewing up brushes like they were sweet-tarts. Now, I'm prone to think I got a bum one, but there's just one thing that makes me wonder whether I'm doing something wrong. On my old generator and this new one, both commutators had little sections that looked like freddy kruger had drug his claws across it. Not across the whole thing, just for about 1/8th of it's circumference. I will admit that I have resorted to using the sandpaper gimmick once to keep my battery fresh (the light came on 40 miles outside NYC the night I came back from Keiths - thanks again Keith!) but even then I used 400 grit wet-dry stuff. Not enough to put these icepick grooves into the commutator. Not to mention that I use the sandpaper on a wide stickwhile the gen is rotating. And this symptom has occurred in BOTH generators! Just a coincidence? Anybody ever get this? I always install the generator just like the book says - the dot meets the line for cooling. I've been very carefull about the brushes? Why does tis happen? Keith, you mentioned undercutting with an xacto knife. How exactly do you do that? Is that for cleaning out the front-to-back grooves? Do those need to be cleaned out? While I was at it, I checked the resistance of my d+ wire. Red to D+, black to GND. Only 10-11 ohms (VOM WAS set to Rx1, and pre-adjusted) I compared this to my new VR (uninstalled) and measuring across D+ to DF I only got 18 ohms. Am I measuring the wrong place with this new one. Jim I thought you said they're supposed to measure 35 ohms? Any thoughts. -M ~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~~ List info at http://www.vwtype3.org/list | mailto:gregm@vwtype3.org