Alternator Sizing - Amp requirements

I recommend a call to Powermaster. They can share alternator output curves and you can pick from there. As @67Dart273 notes above, 1-wrie alternators need a big charge wire. I designed up my own wiring like you are planning to and since I have a 1-wire alternator, I ran a 4-ga wire from the alternator all the way back to battery in the rear. (I have it fused on both ends in case of a short anywhere!) With a 95A alternator, I can tell you that at 1000 engine rpm, and with 2 electric radiator fans (approx 35A total), 1 trans cooler fan, and all headlights/brake lights on, the voltage measured at the battery matches the voltage up at the back of the alternator so the 4-ga wire is apparently doing the trick in terms of minimal losses. I share this just to say the 95A rated output is sufficient for the loads I note.