All valid points Mr Vspec - I'm not convinced the bobbins are needed for the rectifier either and indeed HD replacement unit users also report no problems when solidly mounted.
Anyone know why these bike engines need such a mahoosive rectifier anyway? Cars have them build neatly into the alternator and they can be very small indeed. Do we really need a kilogram of electrical gubbins to control a relatively weedy 38amp output?
The bigger Cycle Electric rectifier supplied as stock on the M3W are supposed to have a feature that lets them adjust the voltage to the load. I think it was this 'feature' that caused a certain amount of failures. They are known as being on the delicate side. Whether that is electrical or mechanical is a good question.
The H-D unit doesn't use that system. It is a brute force rectifier that is always cranking out at 100% and any voltage not needed is just dumped to ground. It weighs less and has a thinner profile. Me like.
