Saturday, August 14, 2010
Eolian's original alternator was equipped with a non-standard pulley - larger than the regular automotive one. The adjustable bracket that holds the alternator was designed to fit using this pulley. That is, standard belts worked with it. When that original alternator failed, I replaced it with a standard 80 amp automotive alternator, with a standard pulley*. But now the belts available were either too short or too long.
The fix? Remanufacture the alternator bracket. I took several pictures of the front of the engine, with the alternator in various positions. I enlarged these until they were life-sized, and then laid out a new bracket on them. The end product used portions of the original bracket (to avoid machining), with a segment spliced in. Welded up and painted, it looks pretty good,and it works great.
* Most diesel engines (having no distributor) use pulses from the alternator to run the tachometer. When you change the alternator pulley (or switch to an alternator with a different number of poles), the tachometer will need to be recalibrated.