replacing stator with $40 GM alternator

[brokentoe]

Jake, you are one clever dude.

[Roady]

That's an excellent mod, Jake. And a very nice job on the instructions. Kudos.

[jake2012]

How'd you pin the pulley? Any photos of that? Nice clean mod.

Hey I drilled a hole through the pulley right where the key is on the crank shaft . Made the pin so it engages the side of the key and the bolt washer holds it in. Make sure you measure good and square the side of the pin to mate with key;also make sure you install it on the side of the key ahead of rotation. I first tried it without this pin and it kept unbolted. Make sure you use a concrete nail for a pin also; it is very strong.

PS the best way to find the spot to drill is to first mount the pulley with some tacky paint on the face of the flange; this will leave the impression of the open area of the crank pulley. You'll then have the spot to drill the hole just inside the impression mark. The pin is about 3/16" if you mess up you can just try another hole on the pulley; but not to many. Oh and make the pin long enough to touch the face of the carank shaft and flush with the outer face of pulley.

[jake2012]

Jake, you are one clever dude.

Thanks brokentoe. The truth is I live on a small fixed income and could never afford a stator so as they say necessity is the mother of invention. It also does'nt hurt to have been a wrench all my life. Thanks again

[jake2012]

looks excellent work...
i do have a simpletons question....
what do you do with the other alternator that the bike has?

Hey OZman I just cut the yellows wire off at the block and sealed them with RTV. One day God forbid I have to open her up I'll just remove the stator for good and plug the hole where the leads come out of the case. Mate!

[jake2012]

Very nice, looks like a shoe horn fit, but the results are excellent.

Hey dangeruss, Thanks! It is tight but there is plenty of adjustability and once you tie back the plug wires ,making sure all hoses and wires are secured and out of the way it's fine. I'll try and get some better pics of the adjuster side of the alternator bracket.

[jake2012]

WOW, that is one SLICK modification...

Thanks! Boufie

[jake2012]

That's an excellent mod, Jake. And a very nice job on the instructions. Kudos.

Thanks Roady! Just tryin to help the brothers out.

[badorderbob]

Really Cool Jake, did mine on an 1100 somewhat like the PO Boy Conversion. My bikes a dresser so everything is hidden. That's a very good job hiding it there!! Bob

[jake2012]

Really Cool Jake, did mine on an 1100 somewhat like the PO Boy Conversion. My bikes a dresser so everything is hidden. That's a very good job hiding it there!! Bob

Hey Badorderbob! Dressers hide alot of stuff but this is the best way to do a nekked. Does yours work poorly like the Poboy or did you use a bigger pulley? a friend mounted the PoBoy kit and his only charged after 1500 rpm.

[Fred Camper]

Mounting it high like that really helps preserve the appearance of the bike. Looks very nice. Did you consider what drive ratio to spin that alternator at, a GL revs a lot higher than a car but your pulley is also smaller to compensate. So as long as you do okay at idle, I think you will be fine when you spin her up. And you kept the budget intact. Good work.

[jake2012]

I did it trial and error in that the size pulley that made it charge good at Idle was the one I went with. As far as spinning at higher rpms I figure a Nascar spins them at 10 ,000 +; I should be ok. I did contact a guy that works at Delco and he talked with an engineer and he said the only posible issue was the brushes were designed for a rotation oposite a GW; however he said it would only slightly reduce the life of the brushes. I had a concern about the reverse fan and he said it will just pull air through instead of the more efficient push of the design. One can replace the fan with a $20 replacement that will push the air through the alt. He also mention that these alts. when hot automatically reduce output until they cool down. I guess time will tell worse case I have to buy another alt and pulley and still big bucks ahead of a stator and/or rectifier replacement. and good ridin.

[Fred Camper]

My bet is your setup is fine. A pusher fan like yours blocks more airflow cause it contacts cooler air than the stock puller and that means the fan will come on a bit sooner at a given heat load. Guys with blowers make it work and you will also.

[jake2012]

My bad Fred, I was refering to the fan on the alt being backward rotating. That $15 Amazon radiator fan is great.

[badorderbob]

Really Cool Jake, did mine on an 1100 somewhat like the PO Boy Conversion. My bikes a dresser so everything is hidden. That's a very good job hiding it there!! Bob

Hey Badorderbob! Dressers hide alot of stuff but this is the best way to do a nekked. Does yours work poorly like the Poboy or did you use a bigger pulley? a friend mounted the PoBoy kit and his only charged after 1500 rpm.

Hay Jake, my alt. is a 1-wire Ultra mini Denso 50 amp, but I did a little try-n-error to get a 2 to 1 ratio. Crank pulley is Don Pigotts' 3.5 he sells with his kit, I was just able to buy the pulley. On the Alt. pulley I came up with a Nascar pulley size 1.75 which gives me a 2 to 1 ratio. I also have a carb conversion which idles at 1150 but I up it to 1200 rpm which gives me 13.8-9. It will also charge higher when it calls for it at 14.2-3 but when everything is working as it should I get a 13.8-9 and that is with everything on,..........Sorry for long story but it works great and I'm glad I did the conversion!!! Bob