I think I may have at least the voltage fluctuation fixed. After reading THIS I learned how important that buss bar at the horn relay is. This is where the main feed to the dash leads from and is connected to the charging system with screw terminals. I took it al apart and used my Dremel with a wire wheel to clean the buss bar and the wire terminals. I put it all together and the gauge did not fluctuate. I took the car for a good 30 minute run. It stil doesn't charge worth a darn with the lights on at idle in gear. Maybe this is normal? I think I'll eventually go with an internally regulated alternator and use relays to run those T3's!
I have had some 60's cars that didn't charge well in gear, lights and heater on. I don't think I'd sweat that too much Todd. It sure sounds like you are on the right track now. Way to go for not giving up!
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1966 Strato Chief 2 door, 427 4 speed, 45,000 original miles
1966 Grande Parisienne, 396 1 of 23 factory air cars