researching ideas for brackets and alternator for non AC

[92EcoDiesel Jetta]

That double alt pulley might also be the same as on a Mercedes Turbodiesel 81-85.  I have essentially the same Bosch alt on mine and I have swapped pulleys around on some of them.

Have you used the Mercedes double pulley in idi VW's? Is the Mercedes double pulley 1/2"? Is the diameter the same as the VW pulley?

[rs899]

No, but I have used a VW pulley on a MB and it worked OK, so it should work the other way

[fatmobile]

fatmobile, did you do the grinding of the AC bracket installed in the engine or removed? I really like what you did going to 1/2 belt with the double pulley. Did that eliminate belt stretch, squealing, and frequent belt tension adjustment? What length belt is needed and does the belt flop or is it steady?

The grinding was done before the bracket was installed.
 
 This setup moves the alternator toward the passenger side so makes more radiator space for the MK1.
 It also uses a fatter pivot bolt than the A1 so the alternator pivot hole doesn't wallow out causing the alternator to tip.

 I didn't have much belt squeal with the stock MK1 non-AC setup, with  the 10mm belt.

 Of course it's better than the MK2 AC setup as far as adjustment and squealing.
I meant to post the belt length in the other post I'll see if I did.
The grinding of the bracket allows the alternator to go down pretty far so the belt isn't real long. No long stretches of belt so the flapping is limited.

 

[92EcoDiesel Jetta]

I really like the turnbuckle adjustment in this post and may copy his idea.

http://www.vwdieselparts.com/forum/viewtopic.php?f=8&t=7018&hilit=alternator+bracket&sid=49784262d1ffa267c84950d4668cea93&start=30

[Dakotakid]

Looks like you need to remove 3/8th inch of material off the alternator mounting material (toward center of engine) provided you have the same shaft/pulley length.....according to my measurements here at home. I like this as I have several of these nice Motorolas which need a job AND you can easily switch back to the original at any time with no permanently cobbled-up components.

[theman53]

yeah, sometimes I am a turd blossom. It was easy enough for me so it must be ok for everyone else too.

[92EcoDiesel Jetta]

Looks like you need to remove 3/8th inch of material off the alternator mounting material (toward center of engine) provided you have the same shaft/pulley length.....according to my measurements here at home. I like this as I have several of these nice Motorolas which need a job AND you can easily switch back to the original at any time with no permanently cobbled-up components.

3/8 is a lot of material to remove! Just have to be careful not weakening the bracket. I have a spare Eco engine with AC that I've been mocking up fitting the bracket and 90 A alternator. I did a bunch of grinding on both the alt and the bracket to drop the alternator down far enough to barely get the stock 13 x 947 AC belt on- pic . I think I am gonna skip the grinding on the bracket on my 92 Eco and just use a longer belt. (note: the IP has to come off to get the AC bracket off)

[92EcoDiesel Jetta]

yeah, sometimes I am a turd blossom. It was easy enough for me so it must be ok for everyone else too.

The turnbuckle is not that stiff and does not act as a structural support for the alternator like the top bar that mounts the alternator to the cyl head. Do you see that as a problem?

[theman53]

The 3/8" removed was because of the pulley alignment not for adjustment. The way I put the turnbuckle on I think it is just as stout as the stock arm. Lasted 40,000 miles *with my old GTI belt that had at least 45 thousand on the belt* and I never adjusted it one time...I think it did ok.

[92EcoDiesel Jetta]

The 3/8" removed was because of the pulley alignment not for adjustment. The way I put the turnbuckle on I think it is just as stout as the stock arm. Lasted 40,000 miles *with my old GTI belt that had at least 45 thousand on the belt* and I never adjusted it one time...I think it did ok.

With the double pulley, I took out all the spacer shims on the alternator and had perfect alignment of the pulleys. I went to a Home Depot and they didn't have any turnbuckles. I remember buying an aluminum hex body type turnbuckle from a different Home Depot before. Searching their online catalog, the open frame type is all they have.

http://www.homedepot.com/webapp/catalog/servlet/Search?storeId=10051&langId=-1&catalogId=10053&keyword=turnbuckle&Ns=None&Ntpr=1&Ntpc=1&selectedCatgry=Search+All#/?c=1&browsestoreoption=0

[bbob203]

Lowes has them for sure i just bought one 2 weeks ago.

[Dakotakid]

Clarification: the 3/8 inch material comes out of the front hemisphere aluminum of the alternator.

[92EcoDiesel Jetta]

Clarification: the 3/8 inch material comes out of the front hemisphere aluminum of the alternator.

Is this 3/8 inch in a different area theman is refering to? His 3/8 inch shifts the alternator for pulley alignment so the alternator mount/ hinge boss must be ground down/shortened.

[ToddA1]

I did a similar mod using a 90 amp alt and threaded end links from McMaster Carr.  It adjusted from the top.  It's been a while, so the details are hazy, but I know I used a non ac bracket.

You can kind of see it in this pic. 

-Todd

[92EcoDiesel Jetta]

ToddA1, that 's a nice setup and clean engine bay! 

I got my mock up of the turnbuckle adjuster done on the spare engine. I used a 5/16 turnbuckle and a 957 mm long belt (10 mm longer than the stock belt). I had to shorten the turnbuckle by about 1/4 inch since it was too long for the 957 mm belt (would not have been necessary if I had  a longer belt, store didn't have a 967 mm). I did the lower turnbuckle eye mount a little differently than theman53 (he made a plate) since it was a little bit less fab work with what's available to me. Pics are self explanatory I think.