Shot some video today with the multimeter connected to the battery, alt. line at the fuse box and at the power line out of the alt.

Before I started i checked the continuity of the white alt wire and it passed. Other than that I changed nothing and all the clips are in the order they happened. From 4:26 to 4:41 the blower was on high. After the third clip I turned the radio, blower up to 4 and even had the head lights on and it was fine. I revved the engine in the fourth clip to see what would happen and it all started over again. Between the last two clips I had to charge the battery for a bit to continue testing.

Can't seem to embed so heres a link

It looks like either the alt has a mind of its own or something else strange is going on. I'm still lost here and the system cannot be trusted at this point. All I do know for sure is that all wiring was good when tested.

 

The battery ground wire attached to the frame looks rusty. Have you tried sanding it to a shiny metallic sheen?

 

The whole wire and the ends are new. The head of the bolt is a bit rusty but the threads, bottom of the head and area surrounding the bolt hole are very clean.

 

I suggest that you replace the alternator.

 

That was the first thing I thought until they tested it. I have to get them to test it multiple times. Its worked and quit in the matter of minutes so something is faulty. This one is under warranty so I can swap it for free if they can get it to fail.

 

I would demand a replacement alternator. Assuming that all of your connections are tight and clean, your voltage tests indicate that a faulty alternator is the most likely explanation.

 

Remove the alternator, take it back to the store, and request a replacement. If they argue, remind them of the results of your many tests and ask for a complete refund so that you can buy a good alternator from a competitor.

 

Sounds like my best bet. I'm going to convert the video to play on the psp so even if it does test good again it doesn't look like I'm the one thats crazy.

 

Good idea about the video.

 

I had them test it and is passed 3 times strait. Then mentioned that i had video of the problem. Instead of watching it they replaced the alt. So all is well now.
Guess I wasted a week looking for other problems I didn't have. At least the gounds are better and I can tell a difference.

Thanks to everyone that helped.