Generator to Alternator Conversion

fuhq64 · Posted: Thu May 01, 2014 5:44 pm Post subject:

Finally got to start the car for the first time. The alternator pulley rubs the belt cover but that seems like it'll be an easy fix. The brackets have little to no movement when running. I decided to run a heavier gauge power wire from the alternator to the starter solenoid instead of utilizing the stock generator to voltage regulator wiring. I also connected the other two wires together with the long male connector from the voltage regulator
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69 Squareback
Still a n00b
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fuhq64 · Posted: Thu May 01, 2014 5:46 pm Post subject:

Like so...and I heat shunk it after

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

One thing I noticed, an I believe I heard it mentioned it before, was a high pitched noise from the alternator when running. What's up with that?
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Still a n00b
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W1K1 · Posted: Thu May 01, 2014 6:41 pm Post subject:

Run a straight edge across the face of the alternator pulley towards the big pulley. Is it straight? Probably not, the squeal is usually the belt rubbing the side of the pulley groove as its running. I had a look at mine tonight it is the same way, it's not out of alignment by much but enough to make noise.

You can hear it in the video

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http://www.thesamba.com/vw/archives/manuals/jim_martin_engine_build.php

1973 super
1965 squareback 1500E
1971 bay window westy- subi swap

fuhq64 · Posted: Thu May 01, 2014 6:47 pm Post subject:

vwt3 · Posted: Wed May 07, 2014 1:36 pm Post subject: Alt Bracket

Any updates on this bracket from 11th hour? Any more being made. Is 40amp the biggest that you can go what about running stereos and other high end accessories. Halogen/Projector lights etc ?

Thx vwt3

68vwfasty · Posted: Fri May 09, 2014 9:45 am Post subject:

I am also interested in some brackets and a recommendation on an alternator.

fuhq64 · Posted: Sat May 10, 2014 8:12 am Post subject:

Link

will update with alternator part number and belt size later
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69 Squareback
Still a n00b
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W1K1 · Posted: Sat May 10, 2014 8:50 am Post subject:

If you want one from the wreckers you can get a 40 amp alternator off the 3 cylinder geo/suzuki. Mine was $20, plus a new pulley i picked up at the local electric motor rewind shop. The belt is a gates 25-7390, 39.58"long used with the 11th hour brackets
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http://www.thesamba.com/vw/archives/manuals/jim_martin_engine_build.php

1973 super
1965 squareback 1500E
1971 bay window westy- subi swap

vwt3 · Posted: Sat May 10, 2014 9:37 am Post subject:

Thanks for the replays, but what about a higher amp alternator? Still no word on update of more brackets ?

fuhq64 · Posted: Sat May 10, 2014 11:53 am Post subject:

68vwfasty · Posted: Sat May 10, 2014 4:30 pm Post subject:

Thanks for the info on the alternator. But I don't have any brackets.

Need someone to either sell some brackets or post a good drawing so I can go get my own made.

W1K1 · Posted: Sat May 10, 2014 5:27 pm Post subject:

You can do it the old DDB alternator kit way, make the generator strap longer and strap the alternator down to the fan housing.
_________________
http://www.thesamba.com/vw/archives/manuals/jim_martin_engine_build.php

1973 super
1965 squareback 1500E
1971 bay window westy- subi swap

smellydirt · Posted: Thu May 22, 2014 8:50 pm Post subject:

has anyone ever used this type 3 Alternator Kit it say it can fit on squarebacks

http://vwparts.aircooled.net/CPR-s-12V-Alternator-...on-kit.htm

W1K1 · Posted: Fri May 23, 2014 8:37 am Post subject:

That's the Chico kit, there was a thread about those on here previously

http://www.thesamba.com/vw/classifieds/detail.php?id=1296042
_________________
http://www.thesamba.com/vw/archives/manuals/jim_martin_engine_build.php

1973 super
1965 squareback 1500E
1971 bay window westy- subi swap

vwfye · Samba Member Joined: April 15, 2000 Posts: 7661

VeeDub Fasty · Posted: Fri May 23, 2014 10:31 am Post subject:

supersuk · Posted: Wed Jun 11, 2014 8:41 pm Post subject:

Some of you might know that I purchased a set of 11th hour industries alternator brackets based off of Brents design. These were one of 10 or so prototypes that were made to help determine if these will work or not. Those that have installed them found them to need modifications to the outer metal belt housing in order for it to work. I didn't like the idea of cutting off the thin upper metal portion where the pulley is located, effectively making it flimsy in the affected area. Instead, I decided to modify the magnesium fan shroud and the brackets to make it more adjustable because I know that I will never go back to a generator. The mods that I did still allows a generator to be installed if I ever wanted to...

The original design of the alternator brackets only allowed approximately 1/4" or so adjustment before hitting the metal belt housing. In order to solve this problem, I made modifications to lower the alternator approximately 1/2". This mod allows me almost 1" of adjustment. I could modify it more to allow the full range of adjustment that is set by the smaller slotted bracket, but this would require extensive mods to the mag fan shroud.

This is a list of the mods I did.

1. Relocate the hole on the big bracket approximately 1/2" lower. I welded up the original hole and redrilled it.

2. Shorten the small bracket and adjust the angle of the slot to match the range of the relocated alternator. Basically cut, grind and weld back together. At first, I thought that I could get away by cutting out a pie on one side and rewelding it, but later decided that shortening would be best.

3. Cut both sides of the mag fan housing to facilitate the alternators range of motion. This wasn't too hard with my grinder and 4.5" 1/16" cutoff wheel. All I did was measure and cut until my alternator was able to match the lowest portion of the slot in the smaller bracket. The picture is a little hard to see because of the color of the fan shroud.

Here is a pic of the lowest position.

Here is a pic of the highest position. I could get approximately 1/4" more upward travel, but i'd have to shave down some small tabs on the face of the alternator right behind the pulley. These small tabs hit the thin portion of the metal belt housing. I'll just wait and see if i'm able to install a belt and adjust it first before doing the mods. I have not put this on an engine yet, so don't know if this works. If necessary, I can also reposition the hole on the large bracket lower to gain even more travel. I'll do that if necessary.

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68 Fastback Build: http://www.thesamba.com/vw/forum/viewtopic.php?p=5396323#5396323

EatACactus · Posted: Mon Jun 30, 2014 4:42 am Post subject:

Hey guys, sorry for falling off the face of the earth. I started a new day job a few weeks ago and have been slammed with a million side jobs at the shop that have kept me from dedicating any real time to the brackets.

I now have a set of stock cooling tins, thanks to Samba member Eyetzr. That I'll be able to get much more accurate fitment on for my test purposes. I'm trying to get a new work bench built up in the shop that will give me a better place to work on my test motor, and hopefully make it easier to spend a few minutes here and there on development.

Thank you again to everyone who's taken the time to get the prototype brackets to work. I'll absolutely be using the feedback on the next revision.

Overall it looks like I need to get the following sorted;
Lower mounting hole on large bracket.
Shorted pivot bracket
Sharpen bend on large bracket
Add gusset to large bracket
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'73 Squareback Bodydrop Build
11th Hour Industries

EatACactus · Posted: Mon Jun 30, 2014 4:44 am Post subject:

Also, W1K1; shoot an email to sales at 11thhourindustries.com and I'll refund you on the missing set of brackets. I was hoping to get you a replacement set, but it looks like it may just be a better idea to refund you until the next revision are ready.
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'73 Squareback Bodydrop Build
11th Hour Industries

Brent · Posted: Mon Jun 30, 2014 6:40 am Post subject:

Hit me up if you need some help with modeling. I've got the basics down in Sketchup now and can adjust the laser cut file.
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69 Fastback Build
Berg5 Build


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Generator to Alternator Conversion
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