I followed the Volvo alternator video mentioned in the first post. A few notes on my experience.
The front bearing went into the front casing easily after I heated the front casing and put the bearing in the freezer. Then, after installing the bearing holder, I put the rotor in the freezer and heated the bearing and was able to install the rotor into the casing.
I was worried about tapping the slip ring on with those skinny legs between the rings and the base, but it is the top, under the slip rings, that you are forcing on to the shaft splines so there is very little force transmitted by the "legs".
Aftter soldering the wires onto the slip ring base (those wires are more resistant than they look) I installed the rear bearing (using the freezer and heating again).
Next the rear bearing holder is inserted in the rear cover, tabs fit into grooves to properly align it. It was tight enough that I had to tap it into place.
(sorry for the fuzzy photo)
Next the front and rear covers where assembled. I used a rubber hammer and a large C clamp to get them close enough together to insert the four screws... then the screws pulled it tight. Make sure the covers are properly aligned and not cocked on way or the other.
I installed the regulator and now I have to test it.