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First, I confess I have not read the entire thread - it is quite long.
But just in case no one mentioned this strategy:
Set up an alternator Kill Switch like the drag racers do and then engage the alternator when you are using the brakes to slow down.
In olden times, there was a Variable Pitch Turbo 400 transmission used by GM in the 50's. The speedometer in those cars had a switch that was made under 5-7 mph. This engaged the high pitch setting in the torque converter. When you pulled out from a stop, you would be in high pitch until 5-7 mph and then it would disengage and revert back to normal pitch.
You would need something like this too so that if you are at a stop light with the brake on, the alternator should still be killed.
So if you could get the alternator to work when the brakes were one AND you were still moving, you could run the biggest 100+ amp alternator since it would act as "dynamic braking." You would want the biggest alternator torque load you could get your hands on.
Of course, the really skilled high mileage driver knows how to drive so that braking is kept to a minimum.
And then there is the condition when using engine braking - foot off gas, car in gear, brake off - as compared to coasting where you have the same except car in neutral.
Still in hilly terrain, this might work nicely and would definitely extend range.
Simplest thing would be a convenient button on steering wheel or shifter where you could hold in to engage alternator because you need the braking.
Tom
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