"The next question is why does it not cut out when the battery is charged but I just realized that since it is charging at 8 volts it probably doesnt recognize full charge and just keeps turning out the amps"
Henry - That's says regulator relay is outta whack - that it is regulating at too high a voltage.
The regulator relay winding senses system voltage. When its set voltage is reached it pulls the regulator contact points open. This interrupts current flow to the generator field which causes generator output voltage to fall. When system voltage drops below set voltage the regulator points re-close, field current to the generator builds and output voltage again increases.
This open/close cycle repeats very rapidly (10 - 15+ times a second) causing the generator output voltage to stabilize at the regulator's set voltage.
Also the points open just enough (a couple thousands of an inch) to break the field circuit. So unlike the cutout relay, you cannot tell whether the regulator is working simply by looking at it.
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