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Oh I completely agree with torque being a main consideration. Is there room in the head to drill and tap for a larger stud? And I understand using a harder bolt if that breaks it can make removing more problematic. Just a bad design for the heft of the alternator. Mark

If you move the bracket connection further out it is going to impart more leverage force on the stud. Mark

This configuration requires a lock washer of some sort as once the stud nut is torqued the heat cycles over time can loosen the nut. Special locks can be used but in my setup there were still stud threads after the nut was in place so I just used a jam nut to lock everything together without...

You really don't want to use a spacer and a longer stud as it will put more load on the stud due to leverage on the stud at the base (cantilevered). Mine has not broken but the nut loosening a tiny bit and causing a rattle. Not a great design. My alt is a 100 amp so not as heavy as the larger...