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My home made pulley for an external alternator

Posted: Mon Feb 05, 2018 8:58 pm
by gervais
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

Re: My home made pulley for an external alternator

Posted: Mon Feb 05, 2018 9:01 pm
by gervais
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

Re: My home made pulley for an external alternator

Posted: Tue Feb 06, 2018 9:21 am
by WingAdmin
That looks really clean. Did you use drawings to machine the pulley? Or just eyeball it?

Any pictures of the completed alternator install?

Re: My home made pulley for an externe alternator

Posted: Tue Feb 06, 2018 10:40 am
by Rednaxs60
Nice job. Have had mine on for 1 1/2 years and nothing gets into the timing belts. Good job on the pulley.

Cheers

Re: My home made pulley for an externe alternator

Posted: Tue Feb 06, 2018 12:43 pm
by gervais
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

Re: My home made pulley for an externe alternator

Posted: Sun Feb 11, 2018 9:57 am
by RoadRogue
nice job, you are going to love the extra amps. 8-)

Re: My home made pulley for an externe alternator

Posted: Sun Feb 11, 2018 12:42 pm
by gervais
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

Re: My home made pulley for an externe alternator

Posted: Sun Feb 25, 2018 12:32 pm
by gervais
where i am now:
the alternator is fixed and working well
14.3 vdc IDLE

Re: My home made pulley for an externe alternator

Posted: Sun Feb 25, 2018 12:40 pm
by gervais
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

Re: My home made pulley for an external alternator

Posted: Sun Apr 01, 2018 2:20 pm
by MNAspencade
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


Re: My home made pulley for an external alternator

Posted: Sun Apr 01, 2018 6:12 pm
by Rednaxs60
Nice job. Like the spacer. Cheers

Re: My home made pulley for an external alternator

Posted: Sun Apr 01, 2018 7:32 pm
by gervais
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

Re: My home made pulley for an external alternator

Posted: Wed Jul 04, 2018 11:11 am
by vtflatlander1
Do you have a diagram with measurements for the pulley and modified washer you made. or did you use the 3 groove pulley diagram in your article and modify the 3 groove to a V groove pulley.
Thanks Fred vtflatlander1@myfairpoint.net

Re: My home made pulley for an external alternator

Posted: Wed Jul 04, 2018 12:05 pm
by gervais
well
look the precedent comments here,you can see the drawing made by hand.
you start from this one,
there is a slight mod to be done after where the key gets inside the OEM crank pulley.

the washer is one of the OEM that is just there when you dismantle.

the center hole is re-done too accomodate the aluminium pulley.i think it was almost 1 inch in diameter.

Remember all of this is Home made ,

at this moment i have 14.1 dc on the road,lot of amps for my needs.

i baught the alternator from RockAuto,but the voltage regulator blew after a while,thats the best exemple of ChiCrap .
Buy a used Nipodenso alternator in scrap yard,an OEM from JAPAN and rebuilt it.they are the best.

i lost many photos here in a hard drive crash here .

i cannot send a video here of the actual setup running,if you have an email i can send it .

gervais

Re: My home made pulley for an external alternator

Posted: Wed Jul 04, 2018 7:59 pm
by vtflatlander1
Thank you for the information I already have the alternator from a Geo Metro it is a Nippondenso. got one leg cut off and it is ready to go. I was getting everything I needed for my 84 1200 when the bike was stolen. Police found it 4 months later stripped. I now have an 86 that works fine but want to do the conversion this summer. I couldn't find the Honda Prelude power steering pulley anywhere in junk yards and Honda doesn't sell it anymore. So I am thinking of having one made. Did the V give you more clearance from the radiator? I have the radiator and fan modified already too. It looks like you have a spacer for the lower radiator hose. What did you use for that. Here is my e-mail
vtflatlander1@myfairpoint.net.
You did a great job on your conversion and it sounds like it is working great too
Thanks
Fred

Re: My home made pulley for an external alternator

Posted: Wed Jul 04, 2018 8:16 pm
by gervais
well
i prefer the V belt a lot more flexible.
the multi-v ,if your altenator just twist a side,the strap will jump over the pulley and the V will not do that.

i did NOT cut the fan blade,here the trick,
unscreew the 3 screews that old the fan motor in his place on his support and
after shim the space between the support AND the motor so the fan will come closer as possible of the radiator .

the first install i did ,i cut parts of the blades ventilator,,,,,,,what an error.
it changed the succion of the fan a lot.


the shim home-made at inlet of the water-pump is my creation so i can use the OEM radiator hose but go at any truck repair shop ,they have these hose in vrac,you must find one as flexible as possible so it will not hurt the radiator output oulet,
am i clear???

english as you can read is not my language


check your email

i sent you 3 videos


gervais


it is not complicated to do,you need also to get the radiator forward ,about 1,1.5 inch .the lower bracker wont work.

you need to extend the bolt,,
did you see my previous photos,
i did 2 adapter also for that ,that can be done easy

Re: My home made pulley for an external alternator

Posted: Thu Jul 05, 2018 10:06 am
by vtflatlander1
The videos look very good nice and clean did you have to modify the plastic shield or did it fit as original Fred

Re: My home made pulley for an external alternator

Posted: Thu Jul 05, 2018 10:43 am
by gervais
the plastic shield or did it fit as original Fred:

what is Fred?

the plastic shield?

explain,send pictures,it will help me understand,

gervais

Re: My home made pulley for an external alternator

Posted: Thu Jul 05, 2018 10:50 am
by gervais
this morning i add to dismantle the intake and carbs.
Problem of float level of bowl.
i will take some pictures

gervais

Re: My home made pulley for an external alternator

Posted: Thu Jul 05, 2018 11:45 am
by gervais
helping photos

just took these pictures,
washer are regular thickness,i am using them as "poor man shim" :-)

gervais

Re: My home made pulley for an external alternator

Posted: Thu Jul 05, 2018 6:24 pm
by vtflatlander1
Gervais Fred is my name. The plastic I am referring too is the lower part of the fairing. The alternator sits inside it. Some guys have to heat and reform it so it doesn't hit the alternator. Others are able to put the fairing back in its original position without any modifications. Your setup looks great. I especially like the lower hose spacer allowing to use the original hose. I don't have any pictures as I am in South Carolina and my bike is home in Vermont.

Re: My home made pulley for an external alternator

Posted: Thu Jul 05, 2018 7:03 pm
by gervais
ok
yes i add to modify the side fairing and using an adapter from a 100/140 Weller welder,you know the Weller in a plastic case for welding electronics hobby!!!

it worked great.

i just finish reinstall all those hardware,my xyl went see in my garage and found me courageous to do all of that alone ,i love it.

you need also to install an manual over ride switch for the fan radiator,do you know that?
many have done it and i did during the time i add to dismantle all of this.

my setup is working great ,,,,,,so far :-)

Gf

Re: My home made pulley for an external alternator

Posted: Fri Jul 06, 2018 9:11 am
by vtflatlander1
Yes I plan on installing a fan manual switch also. Your pictures are great. Thanks for the information. Keep me posted

Re: My home made pulley for an external alternator

Posted: Fri Jul 06, 2018 9:18 am
by gervais