Poor Boy alternator conversion pics and comment


Information and questions on GL1100 Goldwings (1980-1983)
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SteveB123
Posts: 842
Joined: Thu Apr 05, 2012 9:29 am
Location: Winchester, Ontario, Canada
Motorcycle: 1982 1100I, 60A Poorboy, MSD coil

Poor Boy alternator conversion pics and comment

Postby SteveB123 » Sun Apr 12, 2015 9:24 am



Don't we all love pics? I'm currently refitting the radiator, but snapped some pics during the process of fitting a Rare Electrical 3 wire 60 amp unit.
Canadians note: shipped USPS from EBay, quickly, and no duty/brokerage/whatever upon arrival.

Used mostly RoadRogue's instructions. Made a 3/8" steel replacement dog bone upper mount, with the required 5/8" up, 1 3/8" over. Used some bronze bushings to avoid crushing the rubber isolators, no welding required. They're not going anywhere.


12mm threaded rod used as the lower pivot, nylock nuts holding everything solid. Considered using another brace from the end of the pivot, but it seems pretty damn solid. Had to drill out alternator case to accommodate the larger bolt. 15/32 is close enough to 12MM in my shop. Drill press FTW.

Pulley is an off the shelf utility unit, 4", bushed undersized then drilled to 15/32" to fit the longer 12mm bolt.

No gasket used behind timing covers, ribs ground down behind pulley, and tiny headed bolt to secure cover under the pulley. All so rad space-out is minimized.


Wait, what? No gasket! Disaster will befall you and descendants for millennia! Well, no. A bit of RTV goobered (technical term) over the centre gap will keep any stray junk out the belt area. Not pretty, but also UNSEEN, except during this thrilling tale!


Upper mount/adjuster is a 1" split ring pipe mount found at Lowes. It's a bit oversize, but it's also trapped, AND the rod threads straight through it to clamp itself against the frame. A touch of Locktight in the threads, and no worries. 3/8" threaded rod, 3/8" bolt, and some nylocks, and job done.



Tin hacking.


Last edited by SteveB123 on Sun Apr 12, 2015 11:42 am, edited 2 times in total.
Current:82 GL1100 Interstate, 60 Amp Poorboy, MSD coil
Previous: 93 GSX1100F Katana
82 GL500 Silverwing

User avatar
SteveB123
Posts: 842
Joined: Thu Apr 05, 2012 9:29 am
Location: Winchester, Ontario, Canada
Motorcycle: 1982 1100I, 60A Poorboy, MSD coil

Re: Poor Boy alternator conversion pics and comment

Postby SteveB123 » Sun Apr 12, 2015 9:34 am

Worked until my back was sore, the beer was working and pain pills weren't. Still VERY happy with the stand, it keeps everything close at hand.

Note: work area slightly messier now. :lol:

I removed the fan, and cut off the steel shroud, as I'll fit a new modern electric fan when i get around to it. For now, no fan. Mine only comes on during the hottest months, and I want to get this thing on the road.

Also on the agenda today, oil change and summerizing the snow-blower. Hopefully it's time.
Current:82 GL1100 Interstate, 60 Amp Poorboy, MSD coil
Previous: 93 GSX1100F Katana
82 GL500 Silverwing

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RoadRogue
Posts: 1919
Joined: Sun Jun 06, 2010 10:51 pm
Location: Castlegar BC, Canada
Motorcycle: 1997 1500SE

Re: Poor Boy alternator conversion pics and comment

Postby RoadRogue » Sun Apr 12, 2015 11:49 am

This all looks vaguely familiar to me somehow....... :lol: looks to me from the pics that your pully ratio is close to 1:1 ,while it will charge fine above 1500rpm you may want to find a 2 inch pulley for the alternator. Please let us know what fan you decide to go with when you get to it. Good job, keep us posted 8-)
Ride safe, Todd
Over night campers welcome

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SteveB123
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Joined: Thu Apr 05, 2012 9:29 am
Location: Winchester, Ontario, Canada
Motorcycle: 1982 1100I, 60A Poorboy, MSD coil

Re: Poor Boy alternator conversion pics and comment

Postby SteveB123 » Sat May 02, 2015 4:20 pm

Finally, done enough to get back on the road. Fan that was ordered won't fit behind rad, might fit in front but I'm not overly impressed with the aesthetic of that. Plus, fork clearance under full compression isn't good. Spacers ordered for lower rad connection didn't fit either! Sigh.

1500 RPM gets.....happy voltmeter!



Went to a alternator rebuild place (Olde School!) and got taken to class on belts. 2" V belt pulley is no good, to much bend, unless you go to a toothed belt, and even then...so I retained the 2.75" alt pulley and went with a 5" drive pulley. He also gave me a blast for using an electric motor pulley, as the belts are a different cross sectional V from automotive belts. I fixed him by using a link belt! :lol:


Current:82 GL1100 Interstate, 60 Amp Poorboy, MSD coil
Previous: 93 GSX1100F Katana
82 GL500 Silverwing

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Wilcoy02
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Joined: Sun Nov 21, 2010 11:37 pm
Location: Marengo, Ohio
Motorcycle: 1983 GL1100 I purchased 3/16

1983 GL1100I frame with an 80 engine. poor boy installed with C-5 ignition--DIED in Grande Prairie Alberta Canada 8/15


98 valkyrie sold 8/16

Re: Poor Boy alternator conversion pics and comment

Postby Wilcoy02 » Sat May 02, 2015 7:16 pm

You will not be sorry for doing this conversion.

Good Job. There are pics so you must have done it.

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SteveB123
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Motorcycle: 1982 1100I, 60A Poorboy, MSD coil

Re: Poor Boy alternator conversion pics and comment

Postby SteveB123 » Fri May 08, 2015 8:19 pm

One week commute report:
Damn this thing works well now....I've not had it on the battery tender at all, and it still cranks like I'm boosting it from my car...frantic! Zooms too, as the higher operating voltage allows the MSD coil to really zap the plugs at higher revs now.
She sure didn't run like that last year!
Current:82 GL1100 Interstate, 60 Amp Poorboy, MSD coil
Previous: 93 GSX1100F Katana
82 GL500 Silverwing

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spiralout
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Location: Alabama
Motorcycle: 1975 GL1000 (gone)
1980 GL1100I (with '77 1000 engine)
1996 GL1500 SE

Re: Poor Boy alternator conversion pics and comment

Postby spiralout » Sat May 09, 2015 6:00 am

Very cool project. I'd love to see my voltmeter show that at 1500.
About the belts. I had no idea that an electric motor pulley used a different type belt than an automotive pulley. Interesting. Is the linked belt cool to use permanently? The only ones I've seen around here were sold as a universal temp/emergency type belt.

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SteveB123
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Location: Winchester, Ontario, Canada
Motorcycle: 1982 1100I, 60A Poorboy, MSD coil

Re: Poor Boy alternator conversion pics and comment

Postby SteveB123 » Sat May 09, 2015 7:11 am

The ones I'm using are industrial belts, sold for use on shop machines, commercial equipment and similar; I use them on my drill press and Unisaw. Much lower vibration since they don't take a set, much like a chain. OK, identically like a chain, since that really what they are.
Current:82 GL1100 Interstate, 60 Amp Poorboy, MSD coil
Previous: 93 GSX1100F Katana
82 GL500 Silverwing

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Joecop
Posts: 87
Joined: Sat Mar 17, 2012 5:28 pm
Location: Michigan
Motorcycle: 1980 GL1100I
1972 Honda Chopper
1989 Yamaha FZR600
1981 Honda ATC 200cc

Re: Poor Boy alternator conversion pics and comment

Postby Joecop » Sat May 09, 2015 4:17 pm

Cool belt for sure....as Wilcoy said you won't regret it.....I love mine.

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littlebeaver
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Motorcycle: 1981 gl 1100 I , 79 Yamaha XS11
Special, 82 Kawa 750 CSR, 82 Kawa 750 LTD, 03 Kawa Nomad 1500, 99 Kawa Voyager 1200

Re: Poor Boy alternator conversion pics and comment

Postby littlebeaver » Sat May 09, 2015 5:09 pm

I really like the idea you used a 5" pulley at the crank, great idea, sometimes finding the smaller pullies for the alt. is a pain,, love the belt idea too...

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sleepy3103
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Location: Toledo, Ohio
Motorcycle: 1983 GL1100I Interstate

Re: Poor Boy alternator conversion pics and comment

Postby sleepy3103 » Tue May 12, 2015 9:22 am

Man I'd love to do this on my 83, but I don't have the confidence or tools for the fab work. If anyone around north west Ohio is good with fab work wants to help on a project sometime let me know.

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littlebeaver
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Re: Poor Boy alternator conversion pics and comment

Postby littlebeaver » Tue May 12, 2015 10:58 am

The hardest part of the modification for some is the fan mod...I reconfigured the fan and mounted it to the heat shield using 3 brackets made special and such... :shock: :lol: because I'm crazy like that.....Works well man.... Todd, stop rolling your eye's I'm gonna smack you :lol: :lol:

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RoadRogue
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Location: Castlegar BC, Canada
Motorcycle: 1997 1500SE

Re: Poor Boy alternator conversion pics and comment

Postby RoadRogue » Tue May 12, 2015 1:18 pm

littlebeaver wrote:The hardest part of the modification for some is the fan mod...I reconfigured the fan and mounted it to the heat shield using 3 brackets made special and such... :shock: :lol: because I'm crazy like that.....Works well man.... Todd, stop rolling your eye's I'm gonna smack you :lol: :lol:

I didnt say a single word there Beave :lol: :lol:
Ride safe, Todd
Over night campers welcome

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littlebeaver
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Special, 82 Kawa 750 CSR, 82 Kawa 750 LTD, 03 Kawa Nomad 1500, 99 Kawa Voyager 1200

Re: Poor Boy alternator conversion pics and comment

Postby littlebeaver » Tue May 12, 2015 2:40 pm

Preventive strike, aaaaaah :lol: :lol: He's gonna love his alt. conversion for sure,, I dig the belt and the 5" pulley man,,, Freakin awesome... Pioneer man... there is only a hand full of the 1100 dudes with conversions, I'm proud to be one of them,, I had a pulley made special for a dude with a 1000, the bolt hole was a little smaller that the 1100's are...Mow that guy was happy getting his pulley...Wish I knew how to use a lathe, I would make the tarnation out of some keyed pulleys... Then sell them at a fair price....

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RoadRogue
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Re: Poor Boy alternator conversion pics and comment

Postby RoadRogue » Tue May 12, 2015 9:01 pm

You made me laugh Beave. when I did my conversion and turned absolutely every farkel I had on I still had amps to spare. I have been thinking about manufacturing a kit for the 1100 conversion if there is enough interest, biggest drawback is getting a pulley cut at a decent price. 8-)
Ride safe, Todd
Over night campers welcome

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Joecop
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Location: Michigan
Motorcycle: 1980 GL1100I
1972 Honda Chopper
1989 Yamaha FZR600
1981 Honda ATC 200cc

Re: Poor Boy alternator conversion pics and comment

Postby Joecop » Thu May 14, 2015 10:15 pm

Ha farkles!

I feel the same way as Beave. I point that Alt out to everyone who looks at the bike.

For those who are considering it....do it, it is as easy as Rougue's instructions.

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RoadRogue
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Re: Poor Boy alternator conversion pics and comment

Postby RoadRogue » Fri May 15, 2015 1:03 am

Joecop wrote:Ha farkles!

I feel the same way as Beave. I point that Alt out to everyone who looks at the bike.

For those who are considering it....do it, it is as easy as Rougue's instructions.

Aww shucks :oops:


Ride safe, Todd
Over night campers welcome


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