[jackbauer]

First thing i'd say is to take a few pictures of the inside of your charger so we can see how it operates and maybe diagnose the problem and/or point out a few tests. I seem to remember from your videos that its a Lester? If so it will be something like a simple scr rectifier so should not be a big deal to repair.

The ideal plan would be to have the genny charge the pack directly and vary revs acording to load. This means you don't use a charger at all but use the engine rpm to regulate the output. I'm aiming for something like this but mounted on a trailer. It all depends of the design of the generator. Does it change speed to match loads? Ie if you plug something in does it increase rpm?