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You can probably use a nylon locking nut that would stop it from vibrating loose. After testing my ground switch and finding that its still charging a little but survived several days, i'm thinking of just running a 4 wire switch all the way from the alternator to the car and back to the alternator. Shut off all 4 wires and start the car. Then the alternator will be off. If you already have the car running, just switch the car off at the ignition key or use your fuel injector cutoff switch to kill the motor, turn the 4 wire switch off, and then bump start the car.
Also, I think if the alternator is off and the engine running and you want to start the alternator again, just flip the switch and it should start working on the fly. You would only need to do this when you're on a long trip with the alternator off and monitoring battery voltage you see the battery is getting too low, just flip the alternator back on and it will charge up the batt for you to safely get to your destination and then plug in your on board charger.
I've got Sunday off so i might report back on this then, otherwise I might be able to work on it tonight as the fiance works till midnight.
I went to the junk yard and cut off an alternator 4pin plug, i'm going to make a jumper harness for a nice factory look.
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