Aussie style alternator for a type 3

mackaymanx

Here is something I have been working on. This is my type 3 alternator conversion.

http://forums.aussieveedubbers.com/viewtopic.php?tid=78941

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blankmange · Posted: Thu Sep 17, 2009 6:45 pm Post subject:

cool -- what is the alternator from?
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JSMskater · Posted: Thu Sep 17, 2009 9:06 pm Post subject:

yeah that's pretty sweet, but it LOOKS to me like some kind of alternator mated to a stock generator housing with a longer shaft... Confused

cool either way! more details!
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Air_Cooled_Nut · Posted: Thu Sep 17, 2009 9:45 pm Post subject:

JSMskater · Posted: Fri Sep 18, 2009 12:08 am Post subject:

rovingmind · Posted: Fri Sep 18, 2009 8:09 am Post subject:

actually he sat it beside "type 1 generator converted to alternator" as a reference

JSMskater · Posted: Fri Sep 18, 2009 8:48 am Post subject:

dirtsandwich

mackaymanx · Posted: Sat Oct 03, 2009 12:16 am Post subject:

More to come

mackaymanx · Posted: Sat Oct 03, 2009 12:39 am Post subject:

Ok here is my step by step of how to do it.

Start with a type 1 (or type 3) generator.

Strip it down. You will need the bearing housing from the fan end, this is the fixed end (the brush end is the floating end of the shaft). Also the pulley end of the amature shaft.

Cut the armature end off the shaft and remove the commutator, I have shown the two different types of shafts I found in the type 1 generators.

This is what you keep plus the two 6mm screws that hold the the generator together.

mackaymanx · Posted: Sat Oct 03, 2009 2:52 am Post subject:

You need to build up this area of the housing, enough to leave you with 106 to 107 mm once machined back. The type 3 housing will need more as they are undercut more in this area.

As the type 1 generators are undercut at each end you need to trim the pulley end back so the mounting suface aligns properly with the type 3 fan housing. Copy the type 3 housing profile onto the pulley end of the housing and rough out the other end.

Pulley end

Alt end

Next we need some tabs on the side so it will bolt together. The first two I did I just built this up with weld but this way is far quicker.

Now we need to duplicate the front housing of the donor alternator into the VW housing. This is a type 3 housing. Use the 6mm screws to hold the front bearing housing on. Bend and weld them into the field coil holes in the housing.

Drill out the cooling hole in the housing(Yes a hole saw would be a lot easier).

Russ Wolfe · Posted: Sat Oct 03, 2009 6:51 am Post subject:

When you install this conversion on a T-3, do you have to modify the cooling tin going to the 3/4 cylinders?
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mackaymanx · Posted: Sat Oct 03, 2009 7:03 am Post subject:

No mod to cooling tin. This is a straight bolt in, only mod is wiring.

mackaymanx · Posted: Sat Oct 03, 2009 8:19 pm Post subject:

Here is the field coil installed and the screws(original and modified). The diameter of the coil is 100mm, this gives you a housing wall thickness of about 2.5 mm with the VW housing being around 105 mm. There is a very similar NipponDenso alternator which has a 103 mm coil but I thought that a 1mm wall thickness was insufficient.

notchboy · Posted: Sat Oct 03, 2009 8:22 pm Post subject:

mackaymanx · Posted: Sat Oct 03, 2009 9:24 pm Post subject:

Here are the two different types of shafts stubs with the spacer sleeves installed. I won't give exact measurements here as is will just get too complicated. Accuracy and attention to detail is a must with this step. Clean up you stubs carefully and keep any runout to a minimum. A good check is to measure the shaft protrusion at the rear housing before you strip down your donor alternator and compare this as you calculate your sleeve lenght(make sure the pulley is on and tight when you measure this). I found around 23mm for these alternators.

Shaft together with end cover installed. Note tin plate to seal the type 1 end cover. Second roll pin not installed yet as I was still checking shaft lenght.

mackaymanx · Posted: Sat Oct 03, 2009 9:53 pm Post subject:

Once you are happy with everything and have it together it's time for a quick bench test. I ran this at 2200 rpm and got 20 amps at 14.2 volts. I'm sure they will put out more but that is all I ran it up to.

1500king · Posted: Sun Oct 04, 2009 6:37 am Post subject:

save yourself the trouble and pull one from an SP2.

notchboy · Posted: Sun Oct 04, 2009 6:40 am Post subject:

Russ Wolfe · Posted: Sun Oct 04, 2009 7:56 am Post subject:

SP2 alternator was only 30 amps. Might as well stay with the generator.
Mack's conversion is 60 amps, if I read the tag right.
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Aussie style alternator for a type 3
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