OBW/Alternator upgrade-Phase 1

[Bill usn-1]

Here is the simplest form of OBW.
It consist of a Ford alternator mounted on a smog pump bracket and a pair of jumper cables.
set the rpm for the right voltage for the size rod you are using and go to town!!
You can just grab one from a junk yard and bolt it in and use it till it burns up!!
Cheap and easy!!
But that's no fun........

Other build ups.
Rear Disc Jeep D300 OBA OBW Interior PS pump reseal Hydro boost Mirrors Headliner
SOA Bushing replacement Roll cage And of course..FI

[mporter52]

Tease!

[Bill usn-1]

OK here is what I started with.
It was a good looking ford alt from the JY. it has a tag that says Ultima 01-0155. Not sure who sells the Ultima brand but maybe someone can find it and let us know.

[Bill usn-1]

Now for a basic rebuild or freshing up an old alt you can get a kit like this.



But I wanted something a little more so I picked up one of these. It's the 105 amp upgrade kit for a stock ford alt. they also have them for GM's...(that's later) Don't be in a hurry when you order. It took them 3 weeks to send mine out to me!! : mad :



Which comes with these parts.

[Bill usn-1]

Rebuilding an alt is pretty straight foward and simple.
I will only hit the highlights. You can just follow the instructions that came with the kit.
First just pull the 3 - 5/16" screws that hold the case together.



Then separate the 2 halves. the stator (the stationary winding part) should stay with the back half of the case.
You will have the 2 little brushes and springs pop out as you lift the armature out. Don't panic!!

Mine looks all brand new inside huh???
Why would I bother to change it? Well if i didn't then what would I write about???

[Bill usn-1]

So the first thing i had to do was build up the new stator.
it consist of soldering the 3 stator leads and the 1 new red lead since the windings are a little different than stock. It's in the directions with the kit.
here are the 2 side by side.
Note the leads are bent in line with the stator and not sticking straight towards the middle of the alt!! You don't want this stuff rubbing once it's back together.

[Bill usn-1]

Next I bolted in the new brush holder. If you are replacing the bearings just use the proper size drift or a socket and extension to pop them out and install the new ones.



Here you can see the small piece of wire that retains the brushes while you try to assemble the 2 halves.
Very important!!

[Bill usn-1]

So now just reinstall the insulators on the right post and reassemble.

Once it is done and you are sure it is right...spins free with now noise or rubbing sounds...
pull the wire out of the brush holder.

[Bill usn-1]

So now that it's back together...will it work?
Well here is what i have for it right now.



Just hook the + pos and - neg to the bat and gnd terminals. Then hook a wire from the battery + side to the fld term on the alt to energize it.

Here is my open voltage at 1200 rpm.

[Bill usn-1]

So it's 11pm and I need somehing to weld together!!!!

Well this is all I could find at short notice.



So I welded the nut to the outer carriage bolt. Jut to prove it will melt metal!!!



OK Phase 1 is done...
time for phase 2 of the OBW.

[Alan Chatterton]

Bill,
how did this work with the EFI? I am guessin that it is ok just as long as you don not weld on the scout? I did a welder out of the GM alternator by taking the doide out. I couldnt get it very hot, but i think that it was because I only used a 65A alternator. I have been looking for a larger alternator to try, but since I have been wanting to go tbi I didint know if I should even bother.

Alan

[Bill usn-1]

I don't see it being a big issue as long as all the equip is grounded.

If you are broke on the trail anyways and need a welder to get you home......
I wouldn't hesitate!

I Had my new exhaust installed and welded together on my scout with the EFI all hooked up.
It's still running.

I don't think I would try any reverse polarity welding!! : innocent

You can always just use 2 batteries in series and the 1/16" rod.
Then just disconnect the ECM.

Something else to help is to run a large drive pulley and a small driven pulley(alt) to make the alt spin faster at a lower eng rpm.