With frustrations mounting over the inoperable charging system we called Higginsville Avionics Lab in Higginsville, Missouri and they suggested we bring the plane back to them to check their installation of the Garmin 496. We flew down Friday morning and Tech Stanton quickly discovered a fuse holder hidden under the dash that controlled the exciter voltage to the regulator. The fuse holder was damaged and making intermittent contact. Apparently this fuse was installed when the alternator kit was put on years ago. Why it was hidden under the dash we will never know! Stanton installed a circut breaker on the front panel and we are now back in business. Thanks to the great techs at Higginsville Avionics Lab all systems are go!!