Author Topic: Re-Engineered Alternator Tensioner kit (Read 2774 times)

Mark · « **on:** November 22, 2006, 01:34:49 pm »

The '80s / early '90s Jetta dealer-added A/C resulted in a less than effective alternator belt geometry, with only about 100 degrees of belt wrap on the pulley.

This, coupled with a 2 piece stamped alternator pulley, has led to many a squealing / stretched / thrown belt, not to mention more than a few choice words.

By replacing the stamped pulley with a machined pulley, and replacing the V-belt tensioner pulley with a flat belt pulley pushing against the back of the V-belt, belt wrap at the alt. pulley is increased to more than 180 degrees, requiring less tension than the 'stock' layout.

I've just started testing the prototype setup on a '91 NA Jetta, and if it looks like a viable alternative to the V-Belt tensioner, I will be making up a number of 'kits' composed of a new machined alternator pulley, and a flat belt tensioner pulley.. if there's any interest.

The solution is not "off the shelf" and requires some machine work to become a kit, but once 'kitted', its a bolt-on which takes about 30 minutes to upgrade.

If this seems like something you'd be interested in, drop me a line, and I'll get back to you.

Pricing will be dependant on quantities, due to the machine work involved, so I'm just looking for a show of hands at this point.

Please indicate if you would prefer a black iron alt. pulley (yet to be sourced) or a chrome alt. pulley (already located).
Open to questions.
Thanks,
Mark

burn_your_money · « **Reply #1 on:** November 22, 2006, 01:40:10 pm »

If I had AC I would be. The non-AC stuff is annoying enough

myke_w · « **Reply #2 on:** November 22, 2006, 05:53:07 pm »

How can you go wrong? As long as folks can afford it i can't see why you wouldnt sell every one you made. My customers always gripe ab
out thier AC setups, I'd push it on them if it worked better than stock..

BTW, the reason the thing is a problem in my experience is because the lower bracket works its way loose and then deflects inward, causing the idler pulley to ride off camber in the belt line, then the belt ride crooked and you know the rest

BellCityDubber · « **Reply #3 on:** November 22, 2006, 07:19:23 pm »

hell, I'd buy one
I've had a few problems with belts and belt tension since getting my A/C Equipped TD.... I was thinking about taking off the AC but I dont want to molest the car as it's a one owner vehicle....

BellCityDubber · « **Reply #4 on:** November 29, 2006, 10:35:21 am »

anybody hear anything else of this... I'm really curious.

Mark · « **Reply #5 on:** December 01, 2006, 11:40:28 am »

Still in the R&D stage.
I got it mocked up with non-metric belts, but as we all know, the extra 1/4" puts the A/C at the outer limit of adjustment when new.
I've got it dialed in with Conti belts now, which leave plenty of room for future adjustment.
Trying to sell my '86 Audi Turbo Quattro wagon to finance the venture.
($1500 - email for pics)
Otherwise, will make kits available in phases, 5-10 at a time, first come, first served.
I want to have some serious miles on the 'test bed' before release, so for now, nothing left to do but drive... and investigate the legal ramifications of selling a re-engineered system.
Regards,
Mark
[email protected]