Okay - went to Advance, got a 89.5" belt (Drive Rite 895K6, prt # 5060895DR) instead of the stock (w/ factory A/C) belt which is 90.5".
Swapped alternator pulley back for stock and put on the 1" smaller belt. PERFECT! The auto-tensioner range shows it is about mid-way, so it is fine.
With the stock pulley on, gauge inside shows voltage much higher - even with A/C on high, lights and fog lights on, interior lights on at idle, it still has a higher reading than the underdrive alt. pulley did with nothing on, just idling.
Now if only I had just bought an even smaller belt, that pesky smog pump....oh well, thanks for the input guys.