Alternator Kit

[panky]

Ted's latest mod is not for the purists Fed up with carrying a spare battery around after a bit of a breakdown on a very dark very busy road in the rain I decided to drag him kicking and screaming into the 21st century.

The feeble old dynamo just wasn't up to the job of short runs with lights blazing, heater blasting and wipers wiping



So the system got an upgrade

A bit of new bracketry



To hold this in place



Still had to connect the wiring up when this was taken but it took me all of five minutes including taping the old dynamo wires up into the loom. I'm very impressed with the kit which took about an hour to fit from tools out to tools away and it works perfectly

[amgrave]

Just did that myself last Tuesday and all went well. Took me a bit longer as I could not make my mind up as to where to mount the coil and had to pack three washers under the front top alternator bolt to line up the belt. By the way it looks like from your picture you could do with an extra washer under yours. Good upgrade I think.

[panky]

I think you're right about the washer, thanks
I'm not particularly happy with where I've mounted the coil, it secured by one of the rebound stop bolts but there's not much room down there to fix it. I think a but of new bracketry is in order

[stuupnorth]

hi mate
did you use the original bolts to fit the alternator?
or did you fit new ones, if so what size were they?
Cheers
Stu

[panky]

Hi Stu, I needed to use another bolt for the back bracket as the dynamo one was to short, it was one I had in my box of bits so no idea of size sorry. It just needed to be about half an inch longer the dynamo one.

[stuupnorth]

ok mate
cheers for that i'll measure up the bolt holes on the alternator
Stu

[panky]

Get some washers as well, you may need them to pack in between the front bracket and alternator to line the pulleys up.

[stuupnorth]

cheers for that

[kennatt]

mounted my coil on the inner wing,which has the added advantage of moving it away from the heat of the engine,

[amgrave]

I mounted my coil on the inner wing too, under the damper. But i found that there was so much underseal on the outside the coil was not getting an earth so not being sure if it should have one I ran an extra wire from the engine block to the coil fixing bracket. Sorted.

[Pascal]

Hi,

I've received my kit and started to put it in but I'm a bit puzzled because on the alternator I received the small tube on the rear mounting is the other way round compared to the picture above. As a result the alternator doesn't fit on the brackets:

[frame][/frame]

[frame][/frame]

The tube looks welded into the alternator body. Do you think I should cut it flush in order to mount the alternator on the bracket?

Best regards
Pascal

[amgrave]

Hi Pascal. No dont cut it, it is a tight fit in the hole but meant to move so as to take up any slack. Just fit the alternator to the new bracket first with a loosly fitted bolt and then fit a bolt into the front one and pull the alternator mounting hole up to the bracket hole. As you do this the tube will slide in the hole. Once in position tighten them all up but not till then. Hope this helps and is clear enough.

[panky]

I just tapped the roll pin through the bracket until it fitted snugly in the space. Only took a couple of taps with a hammer, but don't go mad and hit it too hard as the alternator bracket is cast I'm pretty sure the coil doesn't earth through the mounting bracket so don't be concerned about the paint and underseal, I test ran mine with it dangling and it ran fine (not recommended)

[gtt1951]

If you compare the picture posted up by Panky, with that from Pascal, someone has welded the "tube" on the back flange, onto the wrong side.
This will never fit and needs to be returned to the seller as "unfit for purpose", holding out for a refund on P&P charges as well.
George.

[panky]

If it has been welded up I agree totally, but the 'tube' is normally a roll pin that finds it's own position when the bolts are tightened up. Have you got another picture please Pascal, a close up of where the tube fits into the bracket.

[Trickydicky]

That "pin" is cast into the alternator body, not welded. It is a locating pivot to allow the alternator bolts to be slackened off while holding the alternator body, to allow you to pull some tension into the fan belt and then nip up one of the bolts. You then, with it held in place can tighten the rest of the bolts.
Unless the rear bracket has a hole the same outside dia as the "pin" I would say the supplier has sent out the wrong type of alternator. If you modify it then have to send it back you may invalidate any warranty claims.

[panky]

If that's the case with this kit then the hole in the bracket should be the same size as the pin allowing it to fit in neatly.

[Pascal]

Well Panky was right: a few gentle taps the Jeremy Clarkson way moved the pin to the other side and the alternator went in neatly.

Just need to mount the coil to the bump stop mounting bolts now, but it's a real pain as the bolt heads are turning free on the other side.

I'm just a bit worried about mounting the coil head down. I hope the lead won't drop off with vibrations.

Cheers
Pascal

[panky]

Well done
I had the same problem with mounting the coil, it's attached to the rebound stop bracket bolt but I'm not happy with it. I've got something in mind and I'll post some pics if it works out.

[bmcecosse]

Mount the coil UPWARDS!!