I had a spare bracket, and i decided to give it a go, to see how easy it was, and what needed to done (and to see how long it will last)
so follow along, as i chop up some junk and tack it to my tb42
First picture is of the alternators, side by side. As you can see, they are the same in dimensions, line up, etc. Except for the rear bolt housing on the EL. It is about 10mm's to short. it will need to be chopped out of the Alternator, and the factory bracket on the motor.
and
First thing to do, was to remove both pulleys of both alternators, and after looking at it, i realized I'd have to machine down the front of the EL alternator, so the pulley off the tb42 would fit, and run in the same alignment. I also spotted that i would need to space the TB42 pully out a fraction so it would not run/rub/contact the EL alternator casing.
Now if i was you, i would get a washer, spacer etc off the shelf if you can, because if you cut it, like i did off the el pully, it must be even/straight cut, otherwise, it will cause the pulley to run in and out as it spins.
cutting the el pulley to get a make the spacer.
The spacer i used, separated
Now here, is what i was talking about, before, where the EL falcon has a raised lip. I cut this off, and then machined it down with my angle grinder.
before with the lip
lip removed, and machined (you can see the spacer, on the shaft)
Now i cut my spacer in half, and added the thinner one to the rear of the pulley, and then i placed the thicker one on the front of the pulley, before adding the EL nut. I also was worried the pulley might slip (over time), so i placed lock tight onto the nut, and hit it up with the nut gun. It might slide, over time, but that will tell.
Now I removed the original bracket off the tb42 and you will find out, that you are going to have to cut about 8mm of metal out of it, as well as cutting 5mm's out of the rear of the EL falcon El casing.
In this picture, you can see the original cut marks to fit the original TB42 alternator, and then you can see where i have hacked it out.
in the picture of the pulley fitted, you can just see how much was cut out of the alternator casting, sorry, i didn't get a better one, i forgot to. I did not cut the front mount at all, so it runs true with the belts fitted.
Bolted back in,
The line up with the other belts is very tight.
Misc information;
You will need to run bolt in the top bracket, but the adjuster will work fine.
Full threaded bolt in the rear of the chopped housing
Now wiring, the factory plug works fine, and plugs direct.
If you wiring had been molested like mine was, (check the below pic), the lower heavier gauge (white wire, brown trace) fit's in the lower side of the plug, while the lighter wire (white with red trace) fits above it. One is a constant twelve volts, the other becomes active one the ignition is switched on/engine started.
your charge wire, and earth stay the same.
Now the review
pros;
cheap. cost me $20 bux for an El alternator, and the std is 100amp, while the chaser spec is 110 amp
east to mod, as it took me about 2 hours and two cans of bundy.
cons;
custom mounts on the alt, means that you will need to mod all you el alternators from hear on out. Most case's your 2 hours from home, and you should be able to get it back, of it stops working.
if you need to run the std tb42 alternator, you will need a 5 to 8 mm spacer to cover the amount of steel you chopped out of the factory mount.
I found it easy, that's how i did it. If you can do it better, post it up with pics in this thread.
I'll will pull it off in 3 monts, and check all the brackets. I'll keep doing this every three months to see if it cracks.
cheers
Jimbob
