Alternator Spark/Smoke

FORZWIN

Pit Stop?
:
2003.5 MSP
Gents,

Hoping you can help me diagnose an electrical issue. My MSP crapped out on me in the midst of prepping our house for baby #2 so my time to be without my DD (and time diagnosing said DD) is pretty limited. Here's what's going on...

1. Car started flashing the dash battery light on start, but would go out within 1/4mi of driving. Assumed battery was getting weak. Car was also slow to start, supporting my weak battery conclusion.
2. After two days of this, car was dead. No power to the car, including gauge cluster.
3. Installed new battery, same issue. No power to the car.
4. Found 100A fusible link was blown...surprised the hell out of me.
5. Replaced fusible link, connected battery. Immediately heard popping similar to a MIG welder and smoke. Later found this was coming from the Alternator. The top of the bracket that houses the positive terminal of the alternator was glowing red. To be more specific, this is the "L" bracket on the back of the alternator. At the top of that bracket there is a bolt and apparently it had arc'd, removing the bolt at the top.

My question is, where do I go from here? I'm afraid there is a bigger issue, bad ground maybe? I was not aware that the alternator "should" have power with the engine/ignition off.

Some history....
Car has always seemed to have an electrical gremlin. Headlights/dash lights dimming randomly, rough idle with accessories, overcharging (18v) if run through a decent puddle (blowing both low-beams), etc. I'm hesitant to install a new alternator for fear that it will eat that one too. Any help is appreciated.
 
FYI, here's a stock photo of the Denso unit that was on the car. The part that fried is the large black disc at the top of the black "L" bracket

NP_2104163_Bac__ra_p.jpg
 
Thanks for the vote of confidence, I was hesitant to fry a $200 alternator :) Managed to get it back on the road tonight.
 
Check your connection on that positive terminal. Mine was smoking like a mother a week ago and sparking. Turns out that little nut on the terminal had worked its way almost off of the terminal and it was arching.
 

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