alternator conversion

[ehostler]

the 6g wire in my truck came from my Haynes manual. The 4g for the 14.4VDC @ 130A came from a calculator on the net, however my PC locked up, before I could bookmark it. I'll see if I can find it again.

[ehostler]

I searched my history and found it. It is located at http://www.paigewire.com/agwirecalc.asp

Just use 1 phase, as single phase calculations may also be used for DC.

[dkn1997]

Item part#/original app Source Price

New Take off alt '02 dodge van Ebay $89.99
130 amp

Connectors,4g wire Pep Boys $20.00
12g wire, shrink tubing

New Voltage Reg MPEVR38SB Napa online $11.99

Connector for VR ECHVRC38 Napa online $7.99

New Alt belt Drive Rite 43" Auto Barn $4.99

Used Pulley GM Local auto $5.00
elec shop

Nut for pulley 14mm 1.50 Sears $1.75
thread Hardware


Total $141.71
*they guy at local auto elec shop did not know exact application
for the pulley, he just knew it was GM. My friend got me
another one and it is off a '69 camaro, so probably most gm
will work here

**on the Vr and connector from napaonline, did not include shipping-but if you order it from the store, you would avoid that anyway.

things I ran into:

-had to cut the two factory spacers for original alt. If I had the equipment to press the bushing out of the new alt, I could have probably avoided this, easy work with a dremel, though. In the photos, you can see the bushing I am talking about sandwiched between two black spacers on top of alt.

-GM pulley fits, but factory nut has a built in washer that has to be ground off, I just got a new one.

-new alt sits closer to block/head than original- have to make all electrical connectons before mounting alt.

-Since alt is close, had to cut positive stud (1/2") my new alt came with factory ring terminal and plastic cover for pos stud. I was able to take apart terminal, solder, and re-use with new wires for positive. If you get one that does not have this, make sure you buy a new big ring terminal, as original one in car is too small. Plastic cover is nice because alt positive stud sits close to block.

-had to rig up connections for factory field terminals. This alt has a special plug. I will probably get this soon, and if you get an alt that is older, it will probably not have this, just two studs that accept regular ring terminals.

-also, ran another pos 4g wire to starter relay-this rendered my factory amp gauge inaccurate (at least more inaccurate than it was) I could be wrong, but I think this is because all the current in the alt is not going directly to it anymore.

Overall, very easy to do, only took a couple of hours and the results are amazing.

[JoeMack2]

I just got the last alternator on E-Bay and I am going to go ahead and put it in my 68 Satellite w/440. Thanks dkn1997, for that list, it's going to be real helpful. I've got a couple of questions about the installation, for you guys. I was looking at the June 2000 Mopar Action issue and there is an article in there about up-grading your charging system. Something was mentioned about putting a fusible link in the extra wire from the alternator, is that a good idea? I have already switched to electronic ignition in my car and I have an electronic voltage regulator, is that the same regulator that was mentioned in the parts list? Thanks

[dkn1997]

fusible cannot hurt you, so I would go for it. About that reg, which one do you have?

I know there is constant output job for when you convert 68and older to electronic ignition. I was running this one before. It says "race only" on it and may have contributed to my old alternator's demise. This one is blue with one female connector and a threaded stud w/nut.

What you need is a rectangular dual field reg. easy to spot because it takes a special plug (triangle shaped)

chrger1970: I do not see many chargers here, or anywhere else I have ever been. There are a couple that go to Bald Hill in Farminville, LI on tuesdays, but that's about it.

If you are looking for charger stuff, there is a guy in FarmingDALE,
His beeper is 516 646 0204. I have been to his house and he has a shed full of charger interiors, steering boxes, etc....as well as a couple of parts cars. Forget his name, though.

[charger_dan]

I jut posted some relevant information regarding fusible links and wire sizes on the thread Alternator Feed Wire: Routing. Take a look.