Generator Woes, burning out new regulators.

[filmfolks]

Hi All,
Short Story, good running 1970 Ghia suffered broken throw-out bearing(PO used cheapo with 1770lb clutch), pulled engine tightened up all the tins heads motor trans mounts, new FF trans too(yummy) , doing the right thing etc.
the generator had the tins installed wrong and a goofy spacer placement and alignment with engine pully was off. Generator bearings seemed ok, maybe slightly worn. Mexico bosh newish brushes in it so rebuilt sometime "recently" before my time.
Process was three weeks. I had replaced the regulator with a new solid state bosch 6 months ago. preventative maint mostly but slightly dim lights sometimes.

Problem
Installed motor hooked up the few wires ( i took pictures too just because).
engine fired up, while doing the timing and carbs started to sputtered and blew the regulator to battery fuse. regulator hot (125) gen hotter than engine (150) in 85+ ambient. got the meter out, normal charging voltage. checked everything, and hooked up the meter , new fuse started it up normal voltage a few revs and high voltage and burned up the regulator. and my Elec distrib. arrg

read the samba for days and days , checked everything 20 times over. Polarized the generator, loosened up the gen pully shims and belt. Fearfully installed new Bosch solid state regulator. spare 009 w new points. Fired it up with voltmeter attached, ran fine. finished the basic tune.
Did this for a couple days while tuning. got the detail work , carbs n linkage dialed , plug wires tidy etc swapped shims in the gen pulley as i was getting some slight fan rubbing noise and the motor area was done, motor running as smooth as it had ever been, better actually. regulator did still seem warm(120) gen at crankcase temp (140-150ish)

Started it up yesterday fired right up, gen got hot quick regulator too coil(bosch blue) very hot motor suttered and stopped.
I let it cool started up coil was dead, hooked up spare beru, motor fired up instantly , voltmeter climbed 13 to 15.5 in a few minutes. I assume the new regulator in blown.

I cannot figure out what is making this happen.
What would fail in the gen? seems it has to be there.
no work was done to the gen save fan shims and pulley shims.
Df terminal spun? bearings letting the armature travel and short?
ground prob in 009? ive run this one before.

The less expensive and less labor solution seems to be a CB or IAP alternator, but figuring out the cause of problem seems logical and may save me from a new burned alternator. What can I look for.

[Dale M.]

How clean are your battery cables and clamps at battery and all other connections.. How clean is surface regulator is mounted on..... Is ground strap at front transaxle mount there and in good shape?
_________________
“Fear The Government That Wants To Take Your Guns"
"Kellison Sand Piper Roadster" For Street & Show.
"Joe Pody Sandrover" Buggy with 2180 for Autocross (Sold)
============================================================
All suggestions and advice are purely my own opinion. You are free to ignore them if you wish ...

[busdaddy]

I'd be testing the Df terminal, as well as the wire between it and the regulator for shorts to ground. Even partial or intermittant ones.
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[earthquake]

Do you have to "Polarize" a VW generator?

Eq
_________________
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[filmfolks]

[filmfolks]

[filmfolks]

[filmfolks]

I orderedd an Iap alternator today and will be pulling the gen out tomorrow and hope for clues.

Funny, I guess your old when you can remember never buying starters alternators and generators for cars just rebuild kits. but the kit and regulator is almost as much as the new alternator.

[Cusser]

[filmfolks]

[Dale M.]

With dual carbs the fuel pump issue goes away.... It is only single center mount carb that the fuel pump may be a issue....
_________________
“Fear The Government That Wants To Take Your Guns"
"Kellison Sand Piper Roadster" For Street & Show.
"Joe Pody Sandrover" Buggy with 2180 for Autocross (Sold)
============================================================
All suggestions and advice are purely my own opinion. You are free to ignore them if you wish ...

[mikedjames]

I can imagine that the easiest way you get this runaway is if DF and D+ are shorted on the generator somehow- at low RPM everything may be normal, but then once the voltage on the generator starts to rise with RPM, the field current increases, so the voltage rises and so on.

If the battery was not holding it back, by drawing current, the voltage would be higher.. But as the battery gets more damaged, its resistance increases so it draws less current, so the final voltage can become yet higher.

And that then damages electronics.
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Ancient vehicles and vessels

1974 VW T2 : Devon Eurovette camper with 1641 DP T1 engine, Progressive carb, full flow oil cooler, EDIS crank timed ignition.
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Gearbox rebuild 2021 by Bears.

1979 Westerly GK24 24 foot racer/cruiser yacht Forethought of Gosport.
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[bsairhead]

The problem with the non-alternator fuel pump is clearance to remove it. You can buy a alternator style pump or replace the studs with bolts.

[filmfolks]