Two main reason for premature voltage regulator failure. One of course is the poor quality and other is more current being handled by the points than they can safely handle and last very long.
On the quality issue, years ago, the two contacts were made of different hardness or material depending on the polarity of the system. That is why older regulators would always state for what ground polarity they were to be used on. Newer regulators will often say, either pos or neg ground . That is a dead give away.
Next, current flow through the field circuit has to pass through those points. If the generator is not matched to the regulator that is one possibility and the other, like a previous poster said, fault in field windings causing excess current to points. A specification would have to be available to make a accurate determination of the current flow.
Also, the points can be resurfaced, cleaned etc just like any set of points like ignition points. Cleanliness super important after working them over. I spray brake cleaner on points to clean them.
If you have the cover off while it is charging, any arcing of those points will give it a very short life. Realize, those regulating points are opening every time the set voltage is reached, then they close again very quickly because the voltage drops. This happens several times a second to maintain a constant set voltage. They claim a electronic regulator (the zenor diode) can open and close a circuit 7000 times a second. That is pretty fast and no moving parts in that. That is not my figures, came from some wizard some place. That is why electronic control is superior to mechanical.
I understand your wanting to stay with a generator as I have one of my tractors original myself. I worked over an old regulator and it has worked out fine. Truth be known though, I kind of wish I had put an alternator on it. Also, might be a good idea to run a ground wire from base of regulator right up to the generator mount .
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Today's Featured Article - Listening to Your Tractor - by Curtis Von Fange. Years ago there was a TV show about a talking car. Unless you are from another planet, physically or otherwise, I don’t think our internal combustion buddies will talk and tell us their problems. But, on the other hand, there is a secret language that our mechanical companions readily do speak. It is an interesting form of communication that involves all the senses of the listener. In this series we are going to investigate and learn the basic rudimentary skills of understanding this lingo.
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