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Further Update
Hey Husker,
It's a 2004 with 54,000 miles on the clock, so I guess it's due a replacement. I'll get a new one and fit it once the alternator is back in.
Regarding the alternator, it's more than just the voltage regulator. Having looked at it closely, I've melted the coil wires that feed up to the rectifier. I sniffed the evidence of melting (aside from the 5-7mm gap in the coil cable) and it was the smell I could smell in the car immediately after the mistake. That was the one thing that I couldn't work out - the awful smell, but managed to get all but the alternator working again.
There are a few places in the UK that will do a reconditioned alternator for £95 as long as you give them your old one, so I think I'll do that...
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