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I reviewed the diagram linked above and made a jumper from the battery to the sense post. I ran out to the boat tonight and reinstalled the alternator. It is working as it should. ~13.5-14 V on both volt meters. Thanks for the great info!

Thanks guys. I was at the boat this morning before I saw your response-I pulled the alternator and took it to my local shop here in town for a quick bench test. It was working as it should. I showed him the pictures of the connections (so I could remember where to reconnect) and he suggested that the PO may not have wired the connections properly to begin with. His main concern was there was nothing wired to the "Sense" post on the VR. I am going double check some of the diagrams on the forum and see if I can confirm correct connections. I know 2 of the three are right

Thanks Jim- I'll have a look next time I am at the boat. Also good advice on the higher clew vs.  size.

When we got the boat, it came with the 155 - common in the Great Lakes. The main challenge I have with mine is forward visibility under sail. I frequently furl it up when there is traffic so I can see where I am going. When I replace it, I will replace with a 135 that is higher cut.

Sona Linn has a Universal 25 XP. The engine charging system seems to be "standard".  She has 200W of solar with a dedicated charge controller charging 270Ah house bank and separate starting battery. I noticed my cockpit volt meter reading above 15 while motoring last weekend- I checked the meter at the nav table and confirmed the same. While plugged into shore power, or under solar alone, I am between 13-14V which is normal. Any thoughts on the root cause? Voltage regulator? If so, where might I look to find it?

Does anyone have any experience removing the horizontal cross bar on their Pushpit? I would like it out of the way to improve egress.  I can definitely cut it out and grind it flush.  I am curious if that might create some unanticipated structural weakness.

+1 On Tim Dry. He was recommended by a friend as an Catalina specialist and did our Mk1 survey last summer.

Just joined the Catalina family on September 1 - Sona Linn, 1986 #41.  We are sailing out of Muskegon.

Came with our boat as a spare when we bought it.  New in box. $150 plus shipping or pick-up in the Grand Rapids, MI area.