Just to follow up.
Turns out the powder coating was not allowing the alternator to be grounded. After putting in new one and getting same results I went on a fun wire chasing hunt all wires tested good.... I read on a bronco board to make sure alternator is grounded, so I used the grounding bolt hole in the back and ran a battery cable to chassis ground. Bingo back in business, never seen the alternator grounded before but what do ya know.
Old alternator with the new smaller pulley and i'am makin volts like a SOB at idle. New alternator will go on the shelf as a spare.
Moral of the story, check your grounds.