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Sounds like you have a poor connection in that circuit. A poor connection can look good with a meter, but once you put a decent load on it, it doesn't deliver the goods. Try running a known good jumper from a solid 24v source and see what you get.

Better than grinding down the tabs, replace the connector so that it fits the 60gs. It's a standard .250 connector.

They are identical. Only the passenger side NEEDS to be isolated ground, but the Army wanted to keep spares simplified, so they required them both to be the same. The condenser isn't needed on either one, and won't hurt on either one. It's just for radio noise suppression.

Very good advice, 90Jimmy. Cleaning connectors, especially grounds, should be the first step with these old birds. Make 'em shiny, and give them a coating of dielectric grease. A lot of problems can be solved that way. And then there's that nasty connection to the fuse block through the...

Listen to da man! It took me about 45 minutes to do this rebuild the first time, and I had never been inside an alternator before in my life. If you can change out a battery and follow simple instructions, you can do this.