Not charging with headlights on

You said something about "green not connected." It won't charge with the green disconnected. If you read the test procedure carefully, the gist is that you need to unhook the green, and clip a wire to the field terminal on the alternator which you just unhooked, and hook that wire to a battery source to see if it's charging. Many guys call this "full fielding" which means that instead of the regulator feeding power to the rotor (field) you are now directly doing so with a clip lead.

This eliminates the regulator and a certain amount of wiring.

If the thing does not show a charge on the ammeter at this point, you need to put a voltmeter directly from the alternator output stud and see what the voltage reads while running at a good fast idle. This will tell you

1--if the voltage has gone above the battery, showing charge

2--if the voltage has gone WAY high, showing that the charge line from the alternator output, through the bulkhead, ammeter, and back out to the battery has a break somewhere.