PROGRESS?

Well, not really.

I guess I'm just gonna have to tear the thing apart and order some parts.  In spite of the Lock-Tite the screws holding the starter clutch to the rotor worked loose.  The holes in the rotor are just too far gone, and it looks like short of replacing the rotor this is going to be a continuing source of aggravation.   The good news is that it's cheaper to buy the whole alternator assembly than it is to buy a rotor.

I did learn what the awful clunking sound was that occurred when you let off the starter button.  Did I mention that sound?  Anyway the starter chain is a little loose and was jumping a couple of teeth on the sprocket sometimes when you let off on the starter, so that's good because it sounded pretty rough, like something was tearing up in there, but that's gonna be a relatively easy thing to correct.

It also looks like some light sanding with very fine grit sand paper and some rubbing compound is going to clean up enough of the rust to at least make it presentable.