Alternator Pulley Design

[GTCarstens829]

I purchased a Bosch T1 alternator for a DC generator project that I am putting together. The alternator shipped without a pulley and I would like to put a 2 groove V-belt pulley on it. I purchased a pulley with a split taper bushing but realized that I have a small problem.

The alternator has an external fan that in a normal installation is held in place by the pulley which is bolted by a shaft nut. The shaft nut pushes the pulley and external fan together which makes the move together. My split taper bushing setup does not necessarily ensure that my pulley is applying pressure against the alternator fan.

Is there a way that I can install the split taper bushing that i'm missing that will hold pressure up against the external fan? I have been unable to find a keyed pulley with a fixed 30mm bore.

Here is a picture of the alternator:

http://www.ebay.com/itm/ws/eBayISAP...0&ssPageName=ADME:L:OC:US:1123#ht_5100wt_1392

 

[patprimmer]

Bolt or weld the fan to the pulley taking care to centralise it. Maybe turn up a locating spigot (like a clutch aligning tool) to use when welding.

Regards
Pat
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[MikeHalloran]

I have had some misadventures with Delco/GM alternators having similar drive arrangements. The pulleys were pressed onto the shaft, squeezing the fan to drive it. The bolt really doesn't do squat. The first replacement was too loose, and failed in 100 miles.

I suggest that you have a thick walled steel sleeve made, maybe with a flange at the fan end, but definitely a tight press fit onto the shaft. ... and press it on real tight. Then buy a bigger taper lock, to fit the OD of the bushing.

The other alternative I might try is tapping the taper-lock you have, for a couple of flat head machine screws driven through the pulley flange from behind, so the pulley becomes part of the taper-lock.






Mike Halloran
Pembroke Pines, FL, USA

 

[GTCarstens829]

I think I am going to try to drill the pulley and bolt the fan to it. This seems like the best solution for situation. I will let you guys know how it goes. Thanks for the help!