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Best starter for Smallcar Bellhousing
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gertiebob
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PostPosted: Fri Jun 13, 2025 2:27 pm    Post subject: Best starter for Smallcar Bellhousing Reply with quote

Syncro with a Smallcar conversion.

I did a search and cannot seem to find a good recent answer to this question.

I am replacing the engine so my engine bay is empty. I figure this is a good time to upgrade the starter. Current one is pretty shabby looking and old.

Is there a good replacement without paying the price SC is asking for a rebuilt one? I see they claim 1.3KW and the ones I'm finding are 1KW. I will pay the price if I need to or if I cannot find a new one (not a remanufactured one).

I don't know what Subaru car/year, etc. Smallcar has based their bellhousing on so I can't do an accurate google search.

Any help on this greatly appreciated!
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Sodo
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PostPosted: Fri Jun 13, 2025 2:43 pm    Post subject: Re: Best starter for Smallcar Bellhousing Reply with quote

Move your starter ground from the far end of the gearbox to “direct” fromthe starter mounting bolt to the chassis.
If could be that (older?) Smallcar conversions needed a stronger starter because they lost amperage grounding across the corroded transaxle bolts.

A ground thats
    1) bolt-to-case
    to
    2) bolt-to-case
    to
    3) bolt-to-case
    to
    4)bolt-to-case
    to
    5)bolt-to-case
    to
    6)bolt-to-case
    to
    7)bolt-to-case


…..seven times….. outdoors, dissimilar metals
is asking for trouble - someday.

Use a single copper cable. $15.
then delete that forward transaxle ground strap.
Id try that before changing the starter.
And with a new starter too.
_________________


'90 Westy EJ25, NEW oil rings (!) 2Peloquins, 3knobs, SyncroShop pressure-oiled pinion-bearing & GT mainshaft, filtered, cooled gearbox.
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered original gearbox
....KTMs, GasGas, SPOT mtb
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syncrodoka
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PostPosted: Fri Jun 13, 2025 2:49 pm    Post subject: Re: Best starter for Smallcar Bellhousing Reply with quote

The smallcar bellhousing uses a starter from a manual transmission subaru. Their part number should point you in the right direction with a Google search since it is a subaru number.
I am pretty sure mine came from the '94 donor the engine came from
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gertiebob
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PostPosted: Fri Jun 13, 2025 3:15 pm    Post subject: Re: Best starter for Smallcar Bellhousing Reply with quote

Sodo, my old starter was working fine. Just UGLY!

Syncrodoka. I never thought of using their part number for a search! I'm not that smart. I see that it does lead to some. Thanks!!!
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Sodo
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PostPosted: Fri Jun 13, 2025 3:42 pm    Post subject: Re: Best starter for Smallcar Bellhousing Reply with quote

gertiebob wrote:
Sodo, my old starter was working fine. Just UGLY!

I'm all for a purdy starter but you should still do this $15 mod to protect your transmission bearings.
And to be ready for the day someday your starter isn't getting the amps it needs.
It's most important if your (older?) SmallCar conversion has no engine ground.

Rather than an engine ground I'd add a 4ga from the starter case to the chassis.
An engine ground is good too - for all your sensors and sparkplugs.
But those are all miniscule current needs, perhaps in the milliamps.
They can easily get milliamps from your alternator mounting bracket.
Not like the starter and alternator. Them'r BIG AMPS. Like 80A, 100A etc.

Does anyone know if modern Smallcar conversions have an engine (alternator) ground?
_________________


'90 Westy EJ25, NEW oil rings (!) 2Peloquins, 3knobs, SyncroShop pressure-oiled pinion-bearing & GT mainshaft, filtered, cooled gearbox.
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered original gearbox
....KTMs, GasGas, SPOT mtb
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gertiebob
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PostPosted: Sun Jun 15, 2025 8:48 am    Post subject: Re: Best starter for Smallcar Bellhousing Reply with quote

Sodo wrote:
Move your starter ground from the far end of the gearbox to “direct” fromthe starter mounting bolt to the chassis.
If could be that (older?) Smallcar conversions needed a stronger starter because they lost amperage grounding across the corroded transaxle bolts.

A ground thats
    1) bolt-to-case
    to
    2) bolt-to-case
    to
    3) bolt-to-case
    to
    4)bolt-to-case
    to
    5)bolt-to-case
    to
    6)bolt-to-case
    to
    7)bolt-to-case


…..seven times….. outdoors, dissimilar metals
is asking for trouble - someday.

Use a single copper cable. $15.
then delete that forward transaxle ground strap.
Id try that before changing the starter.
And with a new starter too.


Sodo, I get it! So, this $15 ground wire: how long, what gauge and to where, exactly. One of the starter mount bolts to where on chassis? Will i need to drill and tap a location?

I have decided to get an adapter from T3technique so I can use NEW (not rebuilt) Bosch SR0425N starter.
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Captain Pike
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PostPosted: Sun Jun 15, 2025 9:17 am    Post subject: Re: Best starter for Smallcar Bellhousing Reply with quote

I went with the part #. dont recall now but saved $100 or so.
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Sodo
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PostPosted: Sun Jun 15, 2025 11:04 am    Post subject: Re: Best starter for Smallcar Bellhousing Reply with quote

gertiebob wrote:
So, this $15 ground wire: how long, what gauge and to where, exactly. One of the starter mount bolts to where on chassis? Will i need to drill and tap a location?.


There's two schools of thought:

A) DOBryan posted a really good pic of the shorter cable method, appx 16"
DOBryan wrote:
Image may have been reduced in size. Click image to view fullscreen.


---- or ----

B) 36" long cable doesn't upset future mechanics who may be looking for a "transaxle ground".

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


If you have a LiFePO4, thus periodic high demands on the alternator,
it makes sense to ground the alternator directly too.
Arguably the alternator ground wire only needs to be as big as the 12v+ output wire.
But if you use a 4ga, from the alternator case you can consider it to be your "backup starter ground".
_________________


'90 Westy EJ25, NEW oil rings (!) 2Peloquins, 3knobs, SyncroShop pressure-oiled pinion-bearing & GT mainshaft, filtered, cooled gearbox.
'87 Tintop w 47k 53k, '12 SmallCar EJ25, cooled filtered original gearbox
....KTMs, GasGas, SPOT mtb
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gertiebob
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PostPosted: Wed Jun 18, 2025 11:25 am    Post subject: Re: Best starter for Smallcar Bellhousing Reply with quote

Okay, adding to the saga here. If you have an older smallcar bellhousing, you cannot use an adapter and new/better starter.

Apparently, the old Smallcar bellhousings had a hole perfectly sized for a different starter than newer ones; one with a smaller snout.

Soooo, my new adapter with starter simply will not work. It physically will not fit. I need to stay with older rebuilt ones or buy a new bellhousing (which I'm not going to do).

Seems like the suggestions of adding a better ground make sense and maybe will give the old starter a little more umph.
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Ggiomett
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PostPosted: Wed Jun 18, 2025 11:45 am    Post subject: Re: Best starter for Smallcar Bellhousing Reply with quote

Gotta love how “performance upgrade” just means paying triple for something rebuilt in someone’s garage. Classic vanlife tax
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