My home made pulley for an external alternator


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gervais
Posts: 217
Joined: Tue Oct 24, 2017 6:49 am
Location: riviere-bleue,quebec,canda
Motorcycle: GoldWing 1984 GL1200A Aspencade

My home made pulley for an external alternator

Post by gervais » Mon Feb 05, 2018 8:58 pm



hi all,
well i decided finally to install an external alternator on my 84,even if the alternator on the bike is working,,i dont trust it so i decided to modify mine during the time it is on my table and i am doing her maintenance (she was not well maintain in shape)

i add a helping hand locally from the brother of my xyl that have a "machine tour" and he built it himself.

i modify also the big washer that goes between the 1 st gear on the crank and the nut that keep it there.
i also change the front bolt for a longer one that is screew more deeper in the crank filet .

i add to made first the hole in the front cover,i made a support on a piece of 2/12 wood and screew in place
Attachments

first test for the pulley
first test for the pulley


same pulley
same pulley


2 cover on the wood support h-made
2 cover on the wood support h-made




nice an slowly
nice an slowly


hole is done
hole is done


pulley and the "modify shim" NO loose in center hole
pulley and the "modify shim" NO loose in center hole


glue to keep the shim in place when you fix the covers
glue to keep the shim in place when you fix the covers


grey tube(yamabond)washer has some spread on it
grey tube(yamabond)washer has some spread on it






gervais
Posts: 217
Joined: Tue Oct 24, 2017 6:49 am
Location: riviere-bleue,quebec,canda
Motorcycle: GoldWing 1984 GL1200A Aspencade

Re: My home made pulley for an external alternator

Post by gervais » Mon Feb 05, 2018 9:01 pm

here you have a little idea of how the pulley is near the cover,,about 1/16 from it.
no dirt should enter the covers from her rear ,,,i hope.

now i am waiting the alternator and gave you a follow up.
thanks for the tolerance for my english,,:-)

gervais
Attachments

little gap between the cover and the pulley ,less than 1/8
little gap between the cover and the pulley ,less than 1/8


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WingAdmin
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Motorcycle: 2000 GL1500 SE
1982 GL1100A Aspencade (sold)
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Re: My home made pulley for an external alternator

Post by WingAdmin » Tue Feb 06, 2018 9:21 am

That looks really clean. Did you use drawings to machine the pulley? Or just eyeball it?

Any pictures of the completed alternator install?

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Rednaxs60
Posts: 1649
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Location: Victoria, British Columbia, Canada
Motorcycle: 1985 GL1200 LTD (X2), 2008 GL1800 (sold)

Re: My home made pulley for an externe alternator

Post by Rednaxs60 » Tue Feb 06, 2018 10:40 am

Nice job. Have had mine on for 1 1/2 years and nothing gets into the timing belts. Good job on the pulley.

Cheers
"When you write the story of your life, don't let anyone else hold the pen"

Ernest

gervais
Posts: 217
Joined: Tue Oct 24, 2017 6:49 am
Location: riviere-bleue,quebec,canda
Motorcycle: GoldWing 1984 GL1200A Aspencade

Re: My home made pulley for an externe alternator

Post by gervais » Tue Feb 06, 2018 12:43 pm

well i used the diagramm of the pulley that was done by hand,
we checked the dimension and found that this one was closer at the actual dimension that we add in front of us.

the pulley is a V groove so we can find a belt in any hardware store in comparaison with multiple V shape belt that are mostly available in auto parts dealer.
i am still waiting for the alternator by mail,,
i should have it by friday and work in the install this week end,,i will take some pictures.

the OEM Alternator will be disconnected BUT the cable will stay there if i add for any reason to reconnect them.

gervais
Attachments

this one i used!
this one i used!


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RoadRogue
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Re: My home made pulley for an externe alternator

Post by RoadRogue » Sun Feb 11, 2018 9:57 am

nice job, you are going to love the extra amps. 8-)
Ride safe, Todd
Over night campers welcome

gervais
Posts: 217
Joined: Tue Oct 24, 2017 6:49 am
Location: riviere-bleue,quebec,canda
Motorcycle: GoldWing 1984 GL1200A Aspencade

Re: My home made pulley for an externe alternator

Post by gervais » Sun Feb 11, 2018 12:42 pm

well
my install of the hardware around the alternator is done BUT it is not connected yet at the cable harness of the bike.
Now i am working on the radiator fan,i tried to fit the OEM there and,,,i dont like one bit the results so i undo what i did.
i orded a small think fan used on automobile and i will install it there,i did not like the strap coming so close at the OEM fan and even cut/modified so i took it off.

all of these mods should be done with patience,,and love for a job well done.
if you want to do a quick job,,thats not for you as they say!!!!!

Someone added a "shim" at the lower part of the radiator:
where is the water pump and the radiator,a spacer,what was his dimensions???

i hae read so much comments about that alternator mod that i am confused!!!!!!



gervais

i have some pictures,,i will send them

gervais
Posts: 217
Joined: Tue Oct 24, 2017 6:49 am
Location: riviere-bleue,quebec,canda
Motorcycle: GoldWing 1984 GL1200A Aspencade

Re: My home made pulley for an externe alternator

Post by gervais » Sun Feb 25, 2018 12:32 pm

where i am now:
the alternator is fixed and working well
14.3 vdc IDLE
Attachments

alternator connector
alternator connector


bracket 1
bracket 1


bracket 2
bracket 2


under the cab,buffed after i cut the round support
under the cab,buffed after i cut the round support


alternator fixed to his fixture
alternator fixed to his fixture


alternator stopper
alternator stopper








gervais
Posts: 217
Joined: Tue Oct 24, 2017 6:49 am
Location: riviere-bleue,quebec,canda
Motorcycle: GoldWing 1984 GL1200A Aspencade

Re: My home made pulley for an externe alternator

Post by gervais » Sun Feb 25, 2018 12:40 pm

just some pictures of my home made adapter for the LOWER radiateur bracket.

i am using washer because they have a specific with so you can play with them for the space between the fan and the radiator .

you can see also that i attached a spair belt with tye-rap of quality if ever the one installed broke


inside the hexagonal tube i used a metric tap to the same size as the one that is welded on the bike,,6 mm i think.
the hexagonal tube are 1/4 size and overbored at 6 mm easy
Attachments













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MNAspencade
Posts: 36
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Location: Jacobson, Minnesota
Motorcycle: 1989 gl1500
1985 Gl1200 Aspencade - sold

Re: My home made pulley for an external alternator

Post by MNAspencade » Sun Apr 01, 2018 2:20 pm

Congrats on getting your alternator setup working. On the lower radiator supports I used a pipe hanger available at the local hardware store. I believe the idea was posted elsewhere on this site ( by WA ???). It allows for adjustment fairly easily. I hope the pics will help anyone considering this mod.

parts needed
parts needed


short stub of old bolt keeps holder from rotating / moving
short stub of old bolt keeps holder from rotating / moving


head of carriage bolt is cut off to size needed for your setup
head of carriage bolt is cut off to size needed for your setup


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Rednaxs60
Posts: 1649
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Location: Victoria, British Columbia, Canada
Motorcycle: 1985 GL1200 LTD (X2), 2008 GL1800 (sold)

Re: My home made pulley for an external alternator

Post by Rednaxs60 » Sun Apr 01, 2018 6:12 pm

Nice job. Like the spacer. Cheers
"When you write the story of your life, don't let anyone else hold the pen"

Ernest

gervais
Posts: 217
Joined: Tue Oct 24, 2017 6:49 am
Location: riviere-bleue,quebec,canda
Motorcycle: GoldWing 1984 GL1200A Aspencade

Re: My home made pulley for an external alternator

Post by gervais » Sun Apr 01, 2018 7:32 pm

well
interesting this pipe hanger,,,,,,,,,
yes since my last post i finished the install here,
i made other mod also ,add a fan just a side of the alternator so at idle it will cool the alternator even if it is not hot here as in Florida or Arizona.

i have 14.2-14.4 idle at 1100 rpm and yet my carburator are not balanced,i am waiting for my first ride in 2-3 weeks here if only that snow could melt enough because we are still in winter here.

i shell post some pictures soon.


i dont regret one bit to have done this and i am grateful too ALL the help and advise i received from person like Ernest and others that i cannot remember all names,


gervais



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