sizzling hot new alternator

[Stu Jackson]

This "kinda" continues here, http://c34.org/bbs/index.php/topic,5842.0.html

Distribution Panel making electricity topic.

bobg's got some "issues" with his electrical system.

[Mike and Joanne Stimmler]

Have you tested your batteries with a hydrometer? They're cheap.
A bad battery would not cause the spark you're getting but could possibly cause the alternator problem if they were "extremely" low on their charge or shot completely. I'm betting on either the new alternator being bad or the wiring issue that you're getting the spark from.
I can't remember if you said whether you connected the alternator to your starting battery to see if that causes it to overheat as well, but that would be worth a shot.

Another 3 cents,
Mike