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Yes, wet stacking will absolutely cause what you are describing.

I got the piece from McMaster Carr. I remember specifying 1/4" thick, but I can put a measuring tape on the unit later.

Its possible the assembly was damaged in transit (or even installation), but this is on my unfielded unit... so I was surprised to see it fail! I've swapped the cables out before on these. At least GMG was sitting on inventory of new cables for the 802.

Here is whats in an 803 thats headed out Saturday, almost all are the 8MR3005C by my memory.

Walked by my NOS unit this morning to see the set cap went for a ride... anyone else ever experienced a random failure unattended on this part? Ill grab a photo later.

I will not even entertain sets with missing or damaged exhaust lids. Just the kind of hassle I don't want to willingly bring into my life. Good luck in getting this puppy worked over and operational though!

I am not sure. User @Suprman had a large amount of the correct alternators in stock... not sure if he still has any but its worth a shot.

Its worth at least that in parts, so you have an out.

Which machine is this going into?

Yes give Gary Jones a ring (y)

That is slick. Good work Kurt.

While the TMs have pretty much all the info you could ever want or need, don't hesitate to ask any pointed questions you come across in this thread... it is yours to do with what you want, after all :)

Some folks love these solutions. Some folks NEED these solutions (health concerns, etc). I'll never adopt them for my personal use, but its great that companies (and individuals) have stepped up to offer solutions to those who want them.

It appears to be 1/4 NPT (so black iron pipe). I don't have any 1/4 BI here, but I do have a right angle elbow I took off a fuel filter assy on an 002 that I believe is 1/4 NPT, and it threaded in fine.

Source 5/16 JIC instead... same thing, just a higher tolerance for the AN part... exactly the same otherwise.

The manual ending -10 is where you will want to start for that. Its the Operator Manual, and goes through all the basics of the machine. https://www.steelsoldiers.com/threads/mep-803a-all-the-tms-you-need.175591/

100%

Yes Inova is still in business. @peapvp is the chap you want to talk with

Well if you can see it in person, thats best. You can look the set over for overall condition (leaking fluids, general visible maintenance condition (corrosion, sounds, etc), with your eyes see that it produces power (and possibly shown under load that it will put out whats on the data plate at...