Re: Increasing Alternator output
The advice I see here about just changing the stator under the flywheel is probably wrong.
The engines that offer different alternator capacities use different stator and flywheel combinations. Sometimes if you change a 16 amp to a 40 amp by changing both, the cover won't fit over it. (1988 XR4 v6, personal experience)
Coupla things come to mind.
If you deeply discharge your battery and don't recharge it with a quality charger immediately, you will greatly reduce both it's capacity and it's life. Mechanical bumps and vibration in a discharged state increase the damage.
There are two ends to this equation, more power, or less draw. I've blown all the regulators out of a 18' 150 horse bass boat with the engine battery supplying 2 depth finders, 2 live wells, bilge pump, and starting power. Fished all day, didn't kill the battery with reasonable management, like cycling the live wells. It was deeply discharged by the end of the day, however.
Possibly a slightly higher trolling speed will help. If it does you could get it by changing prop pitch or venting it.
Prop pitch also effects high speed operation. You could overrev your motor. On the other hand, if you're lugging it now, it could help there also.
Venting will allow the prop to slip at slow speed. If the boat can't get moving at a pretty reasonable speed, the prop may never bite. We vent the props on the big boats all the time. At about 30 mph, the water over the hub pretty well shuts off the vents. When you floor a 150 and it spools up 70 percent or so before the prop bites, you get a neck snapping hole shot.
I feel your pain, or drive, or whatever it is. I like things to work the best they can, to the point of rewinding or rewiring things, or redesigning electronic controls, or whatever it takes to get what I want. You have to do your homework, though. If you have a simple rectifier system, you could probably get away with rewinding the power coils on the stator with one gauge lighter wire and a few more turns, or just more turns if there's space for it. If you get more voltage at low speed, you will also get more at high speed, and you will also get less current at high speed. The over voltage could take out the rectifier if it does not have a high enough back voltage rating. The point is, it's a system, not just independent functions.
hope it helps
John