Will doing these mods cause any premature wearing of the electrisc, does it put a strain on anything?
If not why didn't alfa do this from the start, revving a cold engine to get the charging system to start seems stupid
IMHO this modofication won't affect the lifespan of the electrics. The electrical
accessories are designed to tolerate voltages up to 14,4V, the strain is starting
above this point (affecting mainly the light bulbs).
In order to maximize the battery life the charging voltage (measured at the battery
terminals) should be 13.8 - 14.2 Volts most of the time.
I think this "no charging after engine startup" problem is arised when AR replaced
the supplier of the alternators from Marelli to Bosch (from 04/1988 in the 33
production and 03/1987 in the production of the Sprints, if my sources are
correct). While the Marelli Alternators (with 45A peak output current) are
happy with the excitation voltage thruogh the 1.2W bulb the Bosch alternators
(with 55A peak current in the S2, and 65A peak current in the S3) are require
a little more. The Bosch factory recommendation is 2W bulb for these alternators.
I think AR simply don't wanted to change the production of the instrument clusters,
(by ordering a different bulb) they can save some money...
The S3 cluster is based on the S2 "Borletti" type, there's no difference in their
electronics (minor changes after 04/1992, but that's a different story), therefore
the problem is inherited...