This is a relatively minor project, but it does get rid of an annoying problem that's been going on for years.
Since I did the fuel injection system for the car, the engine tachs so fast that it tends to put a lot of force on the alternator bracket. I tried to remove the old bracket that I had and snapped off the bolt right into the block.
Yeah, I know it looks like you might get it out of there, but hours of trying would not budge it. It just broke again...
Ended up having to grind it off flush, drilling it out, and installing a helicoil.
So now I don't trust that bolt hole as much as I did before. The old alternator bracket utilized only 2 bolts to hold it on, so I decided to spread the load out a bit more by using more bolts for the bracket.
Since the front end was disassembled, I went ahead and sandblasted and powder coated the timing chain cover in black.
I went ahead and replaced the water pump with a black powder coated unit from Summit.
I drew a bracket in CAD and cut it out of cardboard to make sure by bolt holes were aligned with the water pump bolts.
Then I used the plasma table to cut the same part out of 1/4" steel plate.
I decided to have the upper alternator bolt go directly into the head, so had to drill out the alternator boss for the 7/16" bolt.
Here it is test fitted onto the water pump.
The plate is now just a stable platform to attach the alternator arm to. Now to add the arm and test fit the pulleys.
Now to powder coat the steel pieces...
I bought some 304 stainless tubing with an ID a little bigger than 5/16".
I measured the spacing of each bolt to the bracket with a caliper, then turned pieces of stainless tubing into spacers.
One extra hole on the plate is for a stainless steel tensioner to the alternator.
Installing all of the spacers with new stainless bolts, and it turned out pretty well.
I also powder coated the coil mount and traded out my old corrugated radiator hose for silicone elbows and stainless steel tubing.
That alternator is now rock solid. Doesn't move at all when the engine revs...
Rick
Rick (Cobrapilot)
Since I did the fuel injection system for the car, the engine tachs so fast that it tends to put a lot of force on the alternator bracket. I tried to remove the old bracket that I had and snapped off the bolt right into the block.
Yeah, I know it looks like you might get it out of there, but hours of trying would not budge it. It just broke again...
Ended up having to grind it off flush, drilling it out, and installing a helicoil.
So now I don't trust that bolt hole as much as I did before. The old alternator bracket utilized only 2 bolts to hold it on, so I decided to spread the load out a bit more by using more bolts for the bracket.
Since the front end was disassembled, I went ahead and sandblasted and powder coated the timing chain cover in black.
I went ahead and replaced the water pump with a black powder coated unit from Summit.
I drew a bracket in CAD and cut it out of cardboard to make sure by bolt holes were aligned with the water pump bolts.
Then I used the plasma table to cut the same part out of 1/4" steel plate.
I decided to have the upper alternator bolt go directly into the head, so had to drill out the alternator boss for the 7/16" bolt.
Here it is test fitted onto the water pump.
The plate is now just a stable platform to attach the alternator arm to. Now to add the arm and test fit the pulleys.
Now to powder coat the steel pieces...
I bought some 304 stainless tubing with an ID a little bigger than 5/16".
I measured the spacing of each bolt to the bracket with a caliper, then turned pieces of stainless tubing into spacers.
One extra hole on the plate is for a stainless steel tensioner to the alternator.
Installing all of the spacers with new stainless bolts, and it turned out pretty well.
I also powder coated the coil mount and traded out my old corrugated radiator hose for silicone elbows and stainless steel tubing.
That alternator is now rock solid. Doesn't move at all when the engine revs...
Rick
Rick (Cobrapilot)