Home-brewed alternator restoration, possible?

[Tom L.]

I recently was able to find a dated 544 alternator for my '72. I was told that it works but I don't know for sure. At minimum it needs bearings. A few questions:

There is a faint RH stamp that can be seen. Can the case be cleaned with something to make the case look "nice" without destroying the stamp?

If the stamp can't be saved, will a glass beaded finish be somewhat correct? Or is there a process?

Is there a comprehensive rebuild kit available and are any internal parts that may be replaced important to judging?

Thanks!!

[Donald H.]

Re: Home-brewed alternator restoration, possible?

I've done about a half dozen of them, and I have no particular electrical skill. Only what I read.

There are a couple of places that sell overhaull kits with new bearings, diodes, etc. I even had stamps made to stamp the diodes.

I believe the professionals use some sort of tumbling to clean the cases, but I don't have that luxury. Most judges will say glass beading is a no-no. I have tried many different types of cleaner, but nothing seems to get the case back to as originally cast. What I now do is very gently blast with glass (like 40 PSI) to get rid of the staining, and then I work the cases with 0000 steel wool very thoroughly. The steel wool seems to me to get the just blasted look toned down.

I gone through Chapter and Regional judging and did not get any deducts for my alternator.

Don

[Charles I.]

Re: Home-brewed alternator restoration, possible?

I recently was able to find a dated 544 alternator for my '72. I was told that it works but I don't know for sure. At minimum it needs bearings. A few questions:

There is a faint RH stamp that can be seen. Can the case be cleaned with something to make the case look "nice" without destroying the stamp?

If the stamp can't be saved, will a glass beaded finish be somewhat correct? Or is there a process?

Is there a comprehensive rebuild kit available and are any internal parts that may be replaced important to judging?

Thanks!!

I had great luck using WD 40 and a wire toothbrush and a lot of elbow. cast aluminum cleaner on bad spots. don't over do it with that cleaner! stamps are available on ebay. so are the parts. I found the same bearings, seals, capacitor and field coil on ebay also. did the plating myself.
V/r
Charlie

[Mark E.]

Re: Home-brewed alternator restoration, possible?

I sent my case to Ken Bruno to restore the finish and replace the bearings. It didn't cost much.

For a description how they restore the finish, see http://www.kenbrunomotorsports.com/F...Questions.html

I then purchased a rebuilt alternator and transferred its guts into the case.

[Domenic T.]

Re: Home-brewed alternator restoration, possible?

I've done about a half dozen of them, and I have no particular electrical skill. Only what I read.

There are a couple of places that sell overhaull kits with new bearings, diodes, etc. I even had stamps made to stamp the diodes.

I believe the professionals use some sort of tumbling to clean the cases, but I don't have that luxury. Most judges will say glass beading is a no-no. I have tried many different types of cleaner, but nothing seems to get the case back to as originally cast. What I now do is very gently blast with glass (like 40 PSI) to get rid of the staining, and then I work the cases with 0000 steel wool very thoroughly. The steel wool seems to me to get the just blasted look toned down.

I gone through Chapter and Regional judging and did not get any deducts for my alternator.

Don

Don,
I do the glass bead also and use a SS brush a bit bigger than a tooth brush and it works good also. If there are any gouges that need to be filed out, emery cloth (turned around) with the grit against the aluminum, then tapped with a hammer will put the cast texture back in the filed spot. Then a SS brush and it matches great.

Dom

[Tom L.]

Re: Home-brewed alternator restoration, possible?

Thanks for all the input. Anyone have a list of parts that might be needed? If I try to buy a kit I'd like to be sure I have it all. I've seen kits but not sure what they are.

This is not a rush job, too much other stuff to do. Worst case is to drop it to Bruno at Carlisle in August. Thanks!

[Mark E.]

Re: Home-brewed alternator restoration, possible?

Rather than buying individual parts, it may be simpler and cheaper to buy a reman alternator to cannibalize. Bearings are the exception, of course.

[Charles I.]

Re: Home-brewed alternator restoration, possible?

I have a 884 1969 alt. The original one I believe so I went a little above and beyond. Rear bearing had to be the same part number and the regulator is dated. Everything else can be used from a 7127 alternator if I'm not mistaken.

[Bob W.]

Re: Home-brewed alternator restoration, possible?

Tom I think Mark has the right idea, see if Ken will clean the cases.

Bob

[John D.]

Re: Home-brewed alternator restoration, possible?

Hi Tom, If it were my alternator I would just ship it to Ken Bruno. Unless you have the castings professionally refinished they are not as original.
And he has all the equipment to test it, etc.
The one in my '63 looks OK. But you can easily tell it was glass beaded. Not that you can't handle it Tom but just giving my opinion. Thanks, John

[Alan D.]

Re: Home-brewed alternator restoration, possible?

Here is one I did myself (used local shop to clean case) Never changed diodes or bearings so still a little dirty, however
did not suffer (as I recall) a deduct at local show. So it can be done.

[Bob W.]

Re: Home-brewed alternator restoration, possible?

Alan, Great job and how did they clean the case ? That looks like it's new.

Bob

[Alan D.]

Re: Home-brewed alternator restoration, possible?

Knew right after I posted that would be asked, so quick call - he uses a Steel Short Machine (may not be official name) believes many engine rebuilding houses use larger units to do heads, blocks. Uses a very fine substrate like pepper, he's had machine for over 30 years now.

[Bob W.]

Re: Home-brewed alternator restoration, possible?

Alan Thanks , I knew if I didn't ask someone else would. Hope they make a small unit for guy's like you and I.

Bob

[Tom L.]

Re: Home-brewed alternator restoration, possible?

Thanks for all the input. While I'm not in the judging game (yet) but I tend to try to go in the direction of correctness. Mostly I want it to look good but I do drive the car regularly so reliability is just as important.

Anyway, Not sure I love the idea of transferring parts from a rebuilt. My experience with rebuilt is that they are cleaned, repaired and painted. Not necessarily "All new" on the inside.

Chances are that I'll be dropping it off to Bruno in august. Thanks!