Alternator Advice Please

[BLS07]

Cheers Ron!

See attached

One the side on view of Alt.Pivot boss

Second front on view Alt.Pivot boss

A tad extraordinary...!

[Ron Kwas]

BLS;

Extraordinary indeed!

It looks like the front of pivot was substantially ground away...my best guess is this was to accommodate a nonstandard Alt and keep fanbelt plane (sometimes, the Alt casing is cut to achieve this, but it looks like they attacked the engine in this case...??)...in any case, it looks pretty bad and not knowing to what other mechanical insult the pivot might have been subjected to, and weakened by, I'd recommend against trying to put it into service...

That leaves the 3 other holes...I'd try to clear the bolt remains from the fouled one...penetrating oil, center drilling (close quarters drill), bolt extractor...not fun, but about the only option...you could also make an executive decision to abandon the one fouled hole and just use just 2 (presuming they are in good condition to do the job) to hold a bracket which allows mounting either a Bosch Alt (this will take some custom work like removing the pivot on the plate you have and relocating it...not a huge deal but will require some fabrication/welding by a qualified and equipped individual) OR the Delco Alt (one of mine).

The last option is to as I previously mentioned, relocate the Alt to the Dist side with the OEM bracket which was common on RHD vehicles. I don't have PN or detail handy...you'll have to research but pix of this config have been posted here before also...

Derek; Do you have any thoughts to add?

Cheers

[BLS07]

>> anyone not yet checked out https://www.sw-em.com/
You really should.


Heya Ron,

Thanks again for the help with this bizarre sheared Engine casing pivot boss situation.

Having checked out the terrific info on your SWEM site, I noted you mentioned the when mounting an o.e. Bosch alternator using the SwEm Kit bracket there are some considerations re mounting boss dimensions (at bracket fixing point) and the bolt size.

Thinking about how my current Alt. may work with your terrific bracket, I checked the dimensions of the my 55amp alternator.
I purchased the Alt. new from Brookhouse, just hadn't installed it - time/other tasks etc.

Dimensions of mounting boss/fixing points on Alt.

(1) Pivot mounting boss = 27mm
(it's flat both sides, unlike the Bosch image on the SWEM site)

(2) Tension bracket fixing point = 12mm*

Comes with spacer to use at the Tension bar side
(i.e Bolt head>tension bracket>spacer approx 15/20mm>washer+nut)

Could this provide for using your SWEM bracket with some spacers to take remaining space (at rear) at the SWEM bracket pivot mounting point?

Other thought on solutions;

Dynamo bracket
(original, looks in good knick. No signs of warping/obvious fatigue)

- might it be possible to simply repurpose that bracket to house the Alt. ?
- fixing the pivot point with nylock nut at front of Dynamo bracket (front "ear)

As you suggested;
Ideally I'd remove the pivot on the Brookhouse bracket, replace on the other side of the bracket plate. Same placement, essentially, just 'other side of coin'.
Such that it doesn't foul / isn't fouled by the Engine casing pivot boss.

- just don't have the welding set up here..

Cheers Ron and all for your help with this bonkers sheared engine casing boss bollocks!

[Ron Kwas]

BLS;

"Bosch alternator using the SwEm Kit bracket there are some considerations" ...yes, namely that it doesn't work(!), as shown on the Alt Kit Additional info page, and re-engineering would again be necessary...since (I believe) your target is to mount a Bosch Alt (or should be), and you have a bracket in hand, my recommendation would be to make the modifications to that one do the job!

Thanks for the kind words!

[BLS07]

Credit where credit’s due, Ron!
All good!

Yep I hear your point re modification of current Brookhouse bracket, will find a way to get that done.

Cheers & thanks again!

[BLS07]

Looping back here, apologies for the hiatus: extraordinary lack of time.
Unhealthy even!

So, I got some way down the path of flipping the Alt.Bracket pivot bolt to the other side off the bracket. Welded back etc etc

However, it creates a delta with both the top alt.bracket from cylinder head being rendered too short and position of alternator vs belt and timing etc.

Instead, after much thought, I found I could use a GW Fastener spacer at the bottom pivot bolt hole: between engine block & alt bottom pivot.

This aligned perfectly, is robustly secured as it the alternator itself after long and short drives; no play. No signs of where on spacer nor (more importantly) the block itself.

Will add photo of solution, later.

Likewise of re-welded bracket and (my layman’s) scale drawing of the same.

Ron - sorry! Will email you!!

Cheers