Lotus Elan

Alternator Adjustment Strap - source?

PostPost by: pharriso » Fri Apr 21, 2017 10:30 am

StressCraxx wrote:Another method is available from the Denso alternator conversion kits. Instead of a strap, a pair of simple 5/16" rod ends, with left hand and right hand threads, locknuts, and a barrel nut drilled from hex stock to make an adjustable mount.

Photos about halfway down this post:

http://www.lotuselan.net/forums/lotus-electrical-f38/alternative-alternators-t26825.html


That is the hardware provided by Gustafson/ RDent et al with their Alternator conversion. Frankly it's horrible & why I designed my fork bracket. The hardware fouls the alternator and/or dip stick, this is how it installed on my car:

img_2260.jpg and
Look at that stack of washers!


I showed Ray at the last LOG, he showed me the installation on his LoCort & it was no better

In theory the turnbuckle & 2 rose joints is the perfect solution, but the offset between the boss face on the front cover & alternator face puts too much of an angle on the rod. I could not turn the turnbuckle on my installation without the hex hitting the alternator body.
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PostPost by: mbell » Fri Apr 21, 2017 6:25 pm

Personally I did my own small alternator conversion, ~$70 for the 55AMP alternator, even with my limited fab skills was able to make new lower bracket out of some 3/16 steel and adjusting bracket is simple piece of straight slotted aluminum.as top ear of the alternator lines up nicely with the rear of the timing case.

Total cost was around $80...
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PostPost by: collins_dan » Fri Apr 21, 2017 10:28 pm

Phil, I would be interested in one. I didn't like the washer and turnbuckle system either. I went to a junkyard and an old volvo had a fairly heavy straight bracket, which I think I paid a $1 for and bent it and painted it. It's fine, but yours actually looks right. If you don't want to make them, drawings would be great and i will ask my nephew to make one for me. All the best, Dan
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PostPost by: 1owner69Elan » Sat Apr 22, 2017 3:06 am

Here is my setup on the alternator strap. I believe this was supplied by Dave Bean, but Dave Vegher (engine builder) may have done some modification. (Note the Vegher fabricated knurled knob dipstick).

I do note that this particular alternator seems to have a mounting configuration different than the other posts.

Having had an ear broken off the timing case back in the day (ca. 1970) by a loose generator (dynamo) bracket I am sensitive to this bracket not putting undue stress on the timing cover.

img_7579.jpg and


img_7581.jpg and


img_7580.jpg and
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PostPost by: mmatthej1 » Sat Apr 22, 2017 10:41 am

Update :

Have just re-fitted alternator on bottom mountings and swung up to see where the 'Fork' strap will sit - see pix.

It will only fit this way round and I'm not at all happy with the gap at the alternator-end of the strap! I do seem to have a problem with gaps...........

I'm waiting on the post for the items from Kelvedon, so will see how they fit - their top strap just has to suit my car better (I hope!)
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PostPost by: mmatthej1 » Sat Apr 22, 2017 10:42 am

Another pic :
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PostPost by: mmatthej1 » Sat Apr 22, 2017 11:19 am

Prompt delivery from Kelvedon BUT their strap (though nearer) is still not a good fit on my engine!

See fotos but problems are:

1) It's a straight piece of metal and I realise that I definitely need my fitting 'kinked', otherwise the engine bolt would have to be packed out to align - don't want to do this !

2) The adjustment cut-out is right at the end of its travel allowance, when I screw the bolt thru alternator top hole. This might just about be ok but..........

3) The outside end arches round in such a way as to sit behind the alternator fan blades and it touches! I suppose I could file the offending section to a chamfer or even cut off the end outboard of the bolted fitting but neither is ideal.

Cumulatively then, this don't work for me and I think I'm left to either get a piece fabricated to match my broken item OR try to get a Ford TC bracket as illustrated in the earlier piccie from 2cams70 (I'll try this first - any guidance on best source for such TC Ford-related bits, plse?)
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PostPost by: mmatthej1 » Sat Apr 22, 2017 11:22 am

Different piccie:
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PostPost by: 2cams70 » Sat Apr 22, 2017 12:52 pm

I'll take a few photos of the alternator arrangement in an Escort TC tomorrow and will post them. Car has been in shed for 22 years. Cramped and lighting not too good but I'll give it a go!
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PostPost by: mmatthej1 » Sat Apr 22, 2017 1:06 pm

Thanks 2cams70 !

Is there a good (Facebook?) Forum for TC Escorts? I would like to establish availabilty for the 'kinked' bracket asap.
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PostPost by: mmatthej1 » Sat Apr 22, 2017 1:12 pm

Call me Mr. Bad Luck or maybe mechanically inept but now I can't get the Spreader Plate to fit !

Doh!! But it fouls on the bolt of the earth strap on the block ! (see foto)

Surely my earth position must be standard - how do others get theirs to fit?
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PostPost by: 2cams70 » Sat Apr 22, 2017 1:33 pm

With a bit of luck the twin cam adjusting bracket may be the same as a standard crossflow engined Escort - I know the lower 3 point mounting bracket is. Parts manual suggests it is. If that's the case it shouldn't be too hard to source a bracket from an Escort wrecker here in Australia. I've got a standard crossflow engine in the shed also, can't recall if it's still got it's alternator bracket attached but if so I'll check how it compares with the Twin Cam.
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PostPost by: mbell » Sat Apr 22, 2017 3:26 pm

mmatthej1 wrote:Surely my earth position must be standard - how do others get theirs to fit?


That's not the standard earth setup, standard just bridges across the right hand engine mount using the mount bolts.

I have the same/similar alternator as 1owner69 but have might upper bracket to the rear of the mounting lug.
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PostPost by: Lyn7 » Sat Apr 22, 2017 4:33 pm

Hi all. I've been following this thread with some interest. :D My only contribution is, I think the Ford crossflow parts probably will not fit as the crank and water pump pulley has a different off set to the twin cam. Therefore the alternator would have been mounted slightly forward or rearward (cannot remember which). :(
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PostPost by: StressCraxx » Sat Apr 22, 2017 6:35 pm

pharriso wrote:
StressCraxx wrote:Another method is available from the Denso alternator conversion kits. Instead of a strap, a pair of simple 5/16" rod ends, with left hand and right hand threads, locknuts, and a barrel nut drilled from hex stock to make an adjustable mount.

Photos about halfway down this post:

http://www.lotuselan.net/forums/lotus-electrical-f38/alternative-alternators-t26825.html


That is the hardware provided by Gustafson/ RDent et al with their Alternator conversion. Frankly it's horrible & why I designed my fork bracket. The hardware fouls the alternator and/or dip stick, this is how it installed on my car:

The attachment IMG_2260.JPG is no longer available


I showed Ray at the last LOG, he showed me the installation on his LoCort & it was no better

In theory the turnbuckle & 2 rose joints is the perfect solution, but the offset between the boss face on the front cover & alternator face puts too much of an angle on the rod. I could not turn the turnbuckle on my installation without the hex hitting the alternator body.


I agree the bracket by Gustofson is not optimal. It can be improved to suit your purposes.

I used a half height nut on a longer bolt on the timing cover to clear the dipstick. It's not perfect, but another washer or two on the timing cover end an a washer on the alternator bolt should work fine.
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