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I suppose you could put a Klixon type device in the winding or regulator housing and have it interrupt the field current. It would be easier to just kill the exciter, but from what 74m35 is saying, that might actually cause the voltage to spike.

Complaints about alternators failing when attempting to charge a dead or weak battery are common across many applications at least up through he 90's. And a 198° thermostat is still hotter than the 180 and 170° that was common when these trucks were built. But it I get your point. I'll also...

Isolating the alt from engine heat would certainly help the issue. That, and the fact that the alternator picks up its cooling air from the BACK of the radiator. You are running a heat producing item, in a hot environment. If you cool the environment, the cooling capacity of the alternator...

Wrap copper tubing around it and water cool it. The inside of my alternator looked a lot like the one in the original post on this thread. Only wire #5 had come loose from the regulator and arced on EVERYTHING.