My Alternator Project

[Diabolical]

Ok.. I bought this alternator off of eBay for 27 bucks..
Its from a late 80's Suzuki Samurai (I think thats how you spell it)

Its a Mini Denso Alternator
I found a kit to swap it over to a 1 wire for 40.00 including shipping
(I'll post the link later)

Here is the Alt. Not much to look at..
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1039
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1039

I don't like the pulley at all..
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1038
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1038

Something must be done..
While I am waiting for the 1 wire kit to arrive..
Lets do something about this pulley.
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1037
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1037

Having access to a 15" by 40" lathe with a 8 jaw is nice ;)
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1036
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1036

http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1035
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1035

[Diabolical]

Need to face it first
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1034
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1034

Now that its true going to find the center
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1033
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1033

Next, Make it perfectly round
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1032
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1032

Start cutting the groove center and depth
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1031
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1031

Now starting on the sides of the groove
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1030
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1030

[Diabolical]

Looking good!
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1029
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1029

I want to give it some style.. Cutting in a chamfer..
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1028
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1028

http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1027
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1027

http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1026
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1026

Me like
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1025
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1025

[Diabolical]

Need to open up the center for the nut and set the depth..
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1024
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1024

This will work
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1023
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1023

http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1022
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1022

Ok.. Had to flip it around to do the back
This is the only way I know how to make sure its true again..
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1021
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1021

Cutting in a little grove again.. Just to make it look cool
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1020
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1020

[Diabolical]

http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1019
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1019

Sweet!
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1018
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1018

Ok.. Here is what the old one looked like
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1017
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1017

http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1016
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1016

And the new one :)
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1015
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1015

http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1014
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1014

http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1013
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1013

[Diabolical]

Now.. I cant have a nice shinny pulley and an ugly alt right?
Going to take this apart
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1012
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1012

http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1011
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1011

http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1010
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1010

Damn it.. I cant get the windings out..
I wont be anodizing the alt.. It will still look good painted.. (you'll see)

http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1009
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1009

http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1008
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1008

[Diabolical]

Going to clean this bad boy up
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1007
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1007

http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1006
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1006

http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1005
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1005

http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1004
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1004

http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1003
http://www.s10racer.com/board/picture.php?albumid=75&pictureid=1003

[Diabolical]

I will post more later..

[mytmouz]

:cool4:

[434 smallblock]

cool now make me one!!!!!!

[dand355]

nice job , nice tools..... now anodise (?) it....

[Diabolical]

Yes.. It will be green :laugh4:

[onehookinsuv]

MIKE THE MADMAN :stirpot:

[Bacon]

Cool project

[hotrod84]

very nice.

[Joker]

Thats awesome,wish i had a lathe....nice job!

[Diabolical]

Thanks man!!

[smsmith36]

Neat project. I've been a Tool & Die Maker for almost 32 years. That kind of stuff is fun to make and actually pretty easy when you have a whole machine shop at your disposal.

[outlaw84]

Mike that is really cool

[Diabolical]

Thanks again..
Here is is with the bracket I made.. Kinda cool :)

http://www.s10racer.com/board/picture.php?albumid=170&pictureid=1901

http://www.s10racer.com/board/picture.php?albumid=170&pictureid=1899

http://www.s10racer.com/board/picture.php?albumid=170&pictureid=1897

http://www.s10racer.com/board/picture.php?albumid=170&pictureid=1896

[2ndgen10]

MMM I am bored, I know, I am going to build a pulley.... LMAO Mike, You are the Man!