its a maxima swap so the pulley is the Subaru dual belt pulley. All contacts are good. that was the second thing i did.

 

Drove it for a while and everything seems to be doing good, except for the alt not turning on until hit 3k or so part. Tomorrow it is going on a 60 mile round trip to my shop and back, so we will see what happens

From what you say, the alternator appears to be bad. The fusible link may be smoking because of a bad connection to it.

But it DOES charge. One eye's red BRAT does the same thing.

 

And replacing the link fixed the smoking problem

 

And to clarify, after i rev the motor, the alt stays on until the ignition is turned off.

Even though the alternator works after the unit is reved up it shouldn't do what it is doing. Whatever is making this happen the trouble is most likely inside the alternator. You can leave it as is if you want to.

Sounds like a bad "excitor" to me.

 

You either have low exciter input voltage, or the excitor is shot. AKA: It isn't getting signaled to charge, or the excitor that receives the signal to charge isn't working properly. Thats why you have to rev to 3 grand to get it to charge. GM 27si, and 10si alts do this all the time.