type 3 Alternator conversion (my version)

Endangered Species

Thought I would share my version of an alternator coversion...I had a 75 amp bosch alternator laying around, so that's what I went with...I looked up and read every post on this conversion and decided to go with mounting it backwards as seen in many posts...but after test fitting it with the spacer that would be needed to clear the tin and still line up square with the belt and lower pulley (even after cutting the lip off the alternator) it was still going to be to tall to close the enginge cover...So I decided to mount it forward, and here is how I did it....

Max Welton · Posted: Fri Jul 02, 2010 10:14 am Post subject:

How about a picture? Interested in how you arranged for a flow of air through the unit for cooling.

Max
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Endangered Species · Posted: Fri Jul 02, 2010 10:33 am Post subject:

trying to figure out how to post pics on this thing

RyanRodman · Posted: Fri Jul 02, 2010 10:38 am Post subject:

How to post pictures:
http://www.thesamba.com/vw/forum/viewtopic.php?t=6

Endangered Species · Posted: Fri Jul 02, 2010 10:39 am Post subject:

first had to remove exhaust, boot, and tin...
http://www.hubgarage.com/mygarage/vehicles/23917/photos/3147616
http://www.hubgarage.com/mygarage/vehicles/23917/photos/3147620

Mike Fisher · Posted: Fri Jul 02, 2010 10:46 am Post subject:

You should Preview your Posts/pictures before you Submit them.
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Russ Wolfe · Posted: Fri Jul 02, 2010 11:16 am Post subject:

Endangered Species · Posted: Fri Jul 02, 2010 12:05 pm Post subject:

first remove the generator, exhaust, boot, and tin...

Image may have been reduced in size. Click image to view fullscreen.

Endangered Species · Posted: Fri Jul 02, 2010 12:14 pm Post subject:

Next I put the Alternator into the generator saddle and strapped it in to see what I would need to do to make it fit...

then I marked the fan housing were it would need to be modified...don't worry I used an already damaged housing for this mod...

[/img]

Endangered Species · Posted: Fri Jul 02, 2010 12:23 pm Post subject:

I cut this section out with a jig saw useing a metal blade...(little pointer when cutting or sanding soft pot metals or aluminum get yourself a candle and run the blade or sand paper through it regularly while you work and it will keep the blade or sand paper from gumming up)

Endangered Species · Posted: Fri Jul 02, 2010 12:33 pm Post subject:

The cut left an opening that I needed to build some tin for so as to retain the engines cooling...

here is the rough tin which I later cleaned up and reworked

Endangered Species · Posted: Fri Jul 02, 2010 12:46 pm Post subject:

I also needed to relocate the studs for the alternator strap...if you have ever tried to weld on fan shroweds you know it almost impossible, so what I did was to cut the existing studs flush and use them to weld the new brakets to...I drilled holes in the new brackets directly above the flush cut studs for welding...then I welded new studs...1/2" further out and 1" further back on both sides...

Air_Cooled_Nut · Posted: Fri Jul 02, 2010 12:53 pm Post subject:

It's already a LOT of work but just shows there's more than one way to do it. Keep going!
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Endangered Species · Posted: Fri Jul 02, 2010 12:56 pm Post subject:

As you can see I took extra care in making sure everything was square and lined up, and by using the rear half of the cradle the pully location size and belt length remain stock...

Endangered Species · Posted: Fri Jul 02, 2010 1:02 pm Post subject:

I had to modify the hold down stap a little with a little hammer stretching

Endangered Species · Posted: Fri Jul 02, 2010 1:16 pm Post subject:

here is finished product...it has been working great and I driver her daily...it beats the car dying when ever I turn the lights, wipers, and hit the brakes... Laughing

Endangered Species · Posted: Fri Jul 02, 2010 1:24 pm Post subject:

if you decide to do it this way it is a bit of work...it took me about 3hrs or so...now that i know what needs to be done It could probably be done in 1.5 - 2 hrs...

Endangered Species · Posted: Fri Jul 02, 2010 2:04 pm Post subject:

thanks for the help with posting pics guys....

Russ Wolfe · Posted: Fri Jul 02, 2010 2:56 pm Post subject:

Why didn't you just put the small end of the alternator in the saddle, and let the big end hang over the back.
That is the way several other people have done it.
An alternator does not care which way it spins.
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Endangered Species · Posted: Fri Jul 02, 2010 4:07 pm Post subject:

that is what I was going to do but when I got it in there the engine lid wasn't able to shut and I would have had cut the cooling tins and get a longer belt because of spacing up the alt, not only do you have to space it up but also over because it hits the distributer, even after cutting the lip off the alt...in the long run, for me, this was easier and cleaner looking to do it how I did, and I tried the other way first...I had it all in and spaced and the engine lid wouldn't come close to closing and the alt was pretty much against the distributer...I'm not knocking the other way, it is obviously a successful proven way of doing it...My hats off to those who have done it and posted it, it it wasn't for them I might not of even thought of trying it...so a big thanks to all of those that came before


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type 3 Alternator conversion (my version)
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