I would suspect a bad ground or loose connection somewhere in the charging loop that manifests itself as a no charge condition. You mess around with the regulator and re-make the bad connection that goes a while then gets crossed up. The poor connection may eventually take out the regulator because it's grounding or charging through something it isn't supposed to. Example I burnt the speedometer cable off of an EZ-Go golf truckster, the problem was a bad chassis/engine ground cable so it was trying to ground through the speedometer cable, speedo cables don't carry that much juice, much more than 5 amps they get hot and smell bad.
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