Please read the following link first if you have not done this swap:
http://forums.hybridz.org/showthread.php?t=115550
It is the detailed write-up by Hizandherz on how to install an AC Delco/GM alternator si series (10si and 12si). The modification is very straight forward and only requires modifying the lower alternator mount.
In the thread, Nigel brought up the CS144 alternator which has the ability to put out 95 amps at 2000 rpm (alternator RPM) while the 12si only puts our 50 amps. I've been having idle voltage issues with my 12si and it is very evident when the fan kicks on. The idle drops, gets a bit rough, surges, etc., until the fan turns off. Load it up at idle with a fan, lights, and aftermarket stereo and you get the idea.
So I decided to jump right on in and try to get the CS144 to work. Following is a write-up that follows Hizandherz if you want a CS144 instead of a 12si. The CS144 is available on 1992 to 1996 Cadillac Devilles (any Caddy with the Northstar), so if you go to Autozone, ask for one from a 1994 (to play it safe) Deville.
Below are pictures of the 12si and CS144 side by side. Dimensionally they are not much different, but the CS144 is a bit deeper and slightly larger in diameter than the 12si.
The bottom mounting tab is dimensionally the same between the alternators, but the top mounting tab on the CS144 is slightly thicker than that of the 12si. Additionally, the upper mounting tab of the CS144 is threaded for M10x1.5. This will require modifying the stock alternator bracket to allow for an M10 bolt.
All you have to do here is trim the upper mounting tab to the same dimension of the 12si tab.
12si tab - 5/8-in. thick
CS144 tab - 3/4-in. thick. The black mark is my cutting mark.
Finished cutting.
Next, you will need to switch out the serpentine pulley for the L28 v-groove pulley.
Finally, you will have to modify the stock alternator bracket. The slot needs to be widened as mentioned above to fit an M10 bolt, but it also need to be lengthened a bit to allow for a slightly longer belt. You can not use the stock belt as it will be too short and the alternator housing will not clear. I used a Duralast 17360 belt with dimensions of 1.3 cm by 91.5 cm.
Now for the electrical modifications. Never fear, these are easy. To make it stupid simple, go to Napa and get part number EC82. It is an electrical connector that is made to convert si alternator harnesses to CS alternators. It has two connectors, one on either end as shown below. The yellow wire is the exciter and the red is the battery sense. The yellow wire has a resistor attached because the Devilles had a charge light that had resistance to drop the voltage. Simply attach your wires to the new subharness and you are done!
I have noticed that I now charge around 13.1 to 13.3 volts at idle, a significant jump for me. I have yet to fully test it, but this should help out considerably.