I am just using his account at the moment as I haven't got my password with me.
This is alternator conversion for a type 3 that I have been playing with. It uses a NipponDenso alt (this one came from a Diahatsu 3 Cyl Diesel).
MickH ·
I think I have sorted out the mechanical side but this setup is only pushing out about 9 volts.
mackaymanx
GTMac ·
Its because it knows its a 3 cylinder alternator, its missing that extra cylinder to give it 12 volts! 🤓
Whats the reason behind toying with something different?
subimanx ·
It's a good way of installing an altenator on a pancake engine and keeping the "stock" look....and it's better than a generator!!!!! And it just bolts straight on with no mods required except to get rid of the old regulator...👍
68AutoBug ·
First time I've ever heard of anyone using an alternator on a flat VW engine...
it looks good...
LEE
electricmonk ·
Nice to see someone trying over here. I keep procrastinating to myself that I will go to the wreckers and have a look for something to fit at least once a month. From what I have heard the DDB kit uses a forklift alternator and that a few people are using RX7 ones in thier cars in the states. Would be nice to find a cheaper more commonly available unit in Au. Look forward to hearing more.
vw54 ·
interesting conversion
type3lover ·
That's a great idea mackaymanx!!!
I also used a nippondenso alt (from a 90's charade) but I had to clearance the fan housing and massage it a little to fit.
I transferred the VW pulley to it and so far so good.
Your idea is much better I wish I'd thought of it!
Was it you that was going to put edis on your type 3? I've just done it...happy to share ideas :-)
Cylon ·
Weird fact ; Empi guages were made by Nippon Denso.
MickH ·
I've given the housing a bit of a clean up and a lick of primer. The Unipont (NipponDenso copy)alt will be a donor to get this working. The NipponDenso alt was $5 at the dump shop so it was a gamble but it proved the mechanical side of the conversion.
mackaymanx
MickH ·
mackaymanx
Andy ·
Who's hot??
How are you going to cool it?
I'm only guessing from the pics the alternator draws cooling air in over the pulley (were there vents there?), and out over the regulator. Are they still open?
The type 3 generator draws some cooling air from the fan housing that exits out over the brushes, (similar idea to a beetle one) to keep cool.
MickH ·
The type 3 gen does not draw air, it is force fed it from the main engine cooling fan through the hole in the housing(there is no fan in a type3 or type1 gen to draw air). So I don't see there being a cooling problem as the alt still uses the original housing with the cooling hole in it.
mackaymanx
electricmonk ·
I am very interested in this conversion, especially how much you had to fabricate. Is the main shaft from the jap alternator long enough? Is the collar you made a cut from the other side of the jap case? Inquiring minds want to know lol
mackaymanx ·
Ok I,ve got my first one going properly now.
13.8 volts / 15 amps @ 1500 rpm
Here it is next to a type 1 gen converted to type 3 alt.
mackaymanx ·
Here it is sitting on the motor. The output terminal sits down and towards the LH side of the car.
Possible clearance issues with the ignition lead.
Thus is how I have clearanced the housing on the type 1(3) alt to avoid this.
mackaymanx ·
Here is the alt with the terminal to the top. I decided not to go this way as the terminal sits up quite high over the profile of the motor and could lead to shorting issues.
vwsteve ·
good work mate, 10 points for ideas there👍
matberry ·
Well done mate.
Sometimes you dont realise how long it takes to do what you may have thought was an easy mod or fabrication job. ...Meaning hell it can take a lot of time to do these type of mods.
mackaymanx ·
Ok I have 3 of these to test if anybody is interested.
I currently do not have a motor in my notch so I am looking for someone to test them for me.
I will pay for postage down, you get a Alternator for three months then you pay for postage back.
You will need
-original type 3 generator pulley, woodruff key and generator seal
-ability to convert electrical system from generator to alternator use.
I cannot warranty or guarantee these as they are for test.
You get one of these and what you need to supply yourself.
electricmonk ·
LOL Bastard! I would love to test one but my cars still off the road and probably will be for a while now. I take it your going to be selling these after testing? Wish I would have gotten that notch on ebay but a little too much rust for a daily driver. I look forward to hearing more on how these go. Good luck mate
MickH ·
So....what happened to the motor out of your notch....😁
mackaymanx ·
Ha Ha very funny Mick, you know I pulled the motor to put it in my buggy. Only to help you pick up going 1600DP a week and a half later and have you offer it to me!!🤪
mackaymanx ·
Yes I will be trying to flog these off later down the track but first I need some guinea pigs to try them out.
telf ·
Hi mate pm me your ph no. Ill give it a go ive been trying to sus out an Alternator for my square for a while now, this looks like a good adaption
Thanks Telf
vwombat ·
So, you'd need another - maybe kombi - regulator? Did you also test at higher rpm?
My genny has just shat itself (the car's been on the road a week now after several years of basking in dust), and I'd be willing to try,
but I'd also want to buy. How much are you asking if it all goes well?
Guinea Pig #2.
mackaymanx ·
These have internal regulators. I will probably be in Brisbane next week to pick up a car so I will bring them down. No I didn't test at high rpm, I only had the fixed set up which gave me 2200 rpm. I just want to cover costs on these so let me work it out.
vwombat ·
Duh - I thought about the internal regulator just after I posted... NOTE TO SELF _ don't post too early in the morning or your inherent stupidity might kick in.
So, the output terminal is providing DC, as it's post an internal diode plate as well?
So what day do you think you'll be in Brisbane for your pickup? The Type 3's my new daily driver and no genny makes my life a bit complex in terms of getting to work. I suppose I can just take off the belt and run from the battery, but I might need to recharge the thing like a madman..?
electricmonk ·
Just wondering If you still needed guinea pigs? I went out an got a car specifically to do this for you, aren't I nice 😂. But really picking up a new square tomorrow, heads loose and gen is shot. I have a spare engine if I need it but no generator. I realise that I am in SA so postage may be a dampener. I would also be pushing the system as I like my music loud, my old cars genny did not like that at all so may not be the candidate your after
mackaymanx ·
If you want to try one I'll get it to you. That's will be all of them gone.
electricmonk ·
Thanks PM sent. Nice to be riding the crest of the wave with you lot. Here's hoping for the best results possible. Good luck to everyone.
mackaymanx ·
Ok, all of them on their way.
mackaymanx ·
Here are some wiring diagrams on the net. There will be some differences. Some of these state that if the bulb is blown that the alt will not work, this is correct for the original vw alt found in the type 1's but not for these alts as they are excited through the IG wire.
D+ wire at generator should go to the main power terminal on the alternator.
IG goes to the ignition.
L is connected to the DF wire in the engine bay.
Generator regulator is removed or disconnected.
D+ is bridged to B+
DF is bridged to wire 61(this goes to the dash light)
it arrived yesterday during my little girls birthday party. Nice that I got a present too!
I'm on this right now.
I'll post some pics and a report tonight!
mackaymanx ·
Cool, hope all goes well. Just remember to disconnect the battery first before you start to play.
vwombat ·
mackaymanx wrote:Here are some wiring diagrams on the net. There will be some differences. Some of these state that if the bulb is blown that the alt will not work, this is correct for the original vw alt found in the type 1's but not for these alts as they are excited through the IG wire.
PROBLEM!!! Because the RED D+ wire should be sent to both the battery and subsequently the starter solenoid with the standard wiring setup plus the fuse box (by bridging at the voltage regulator), what exactly gets connected to the ignition terminal on the altinator? The light terminal gets the DF GREEN wire, but does the ignition need a new 30 amp wire to the 2nd red (fusebox) connection at the regulator?
D+ wire at generator should go to the main power terminal on the alternator.
IG goes to the ignition.
L is connected to the DF wire in the engine bay.
Generator regulator is removed or disconnected.
D+ is bridged to B+
DF is bridged to wire 61(this goes to the dash light)
The wiring diagram would indicate the splice at the regulator would be enough for ignition... Hmmm... Empty ignition terminal or new wire... Hmmm...
mackaymanx ·
The IG wire goes to the positive side of the coil. So the alt excites when the ignition is turned on.
vwombat ·
Eureka - it's alive! It's ALIVE!!!
Running at a sweet 14.8 to 14.11V at low cold idle and high RPM's. Genny light comes on for ignition and goes straight out as she fires up.
Started up 5 times, all good and kept pumping out the voltage.
It looks like you might be onto something Dr FrankenManx! I'll keep you posted as I road test over the next couple of weeks.
Interestingly, I found some circuit diagrams for these alternators on both a Triumph motorcycle and a light aircraft site among others. Looks like they get around!
Muchos Gracias Amigo!
vwombat ·
I've been idling the engine now for 35 minutes. the alternator is up to 14.12V and not even thinking about getting warm.
telf ·
Hi vwombat i got mine late last week. I was gona fit it over the week end but ran out of time Since you've got yours going could you pm me your ph no so i can confirm what wires go where.
Thanks Telf
vwombat ·
Bring it up if you want. See PM.
Went for a long, fast, hot day run and it's still going like a bought one!
vwombat ·
Sheesh! Somebody deleted my PHOTOS from the camera.
I'll have to go and make some new ones now, and so much for my before and afters!!!
Blood - I want BLOOD!
telf ·
Thanks for your help on the phone last night.
Ill try and get some pics of the before.
and put them up!
electricmonk ·
Mine arrived late yesterday. Hope to be fitting it today.
electricmonk ·
Oh god look at all that smoke!!!!
LOL Just kidding. Installed today and 14.5 Volts. Have not driven it on the road yet but may be able to try it tonight.
mackaymanx ·
ha bloody ha 😂
Good to see they have been a reasonably easy fit. Now we see if they stand up to everyday use.
vwombat you have the alt (003) with the upward facing terminal? make sure you use the the boot on the main terminal (just as a safety measure)
It's on and cruising! You are an official Entrepreneur!
mackaymanx ·
Yeah sure, Watch out Donald Trump! 👍
Just wanted to check on that alt as I assembled it with the terminal upward as it has a shorter terminal.
electricmonk ·
Mate I think these would sell quite well. The install took all of twenty minutes. You could be on a winner
Took the car for a spin tonight and all went well (apart from the blasted timing on the 009. After a good drive still 14.5 volts.
telf ·
Finally got it in the car. It was pretty straight forward. It took me a bit more than 20 mins, but i was messin about doing some other small stuff whilst i had the alt off the car. Whilst idling it was on about 13.25. Cant wait to put it in to daily use.
Ill keep you up to date!
Thanks Telf
Sorry but forgot to take some picks
electricmonk ·
Still going strong, got a couple of drives in before rego expired. Crappy 009 gave me hell but Alternator works a charm. Might be a week or so before she is on the road again
telf ·
Still Going strong!!!
electricmonk ·
Same here.
mackaymanx ·
How about some pics guys.
electricmonk ·
ummm...But I haven't done my hair. Seriously though I should be able to take a couple this week
brightsparq ·
Cool idea just wondering what the output amperage is ?
mackaymanx ·
They should be about 45 amps (from early swift/barina). I can get a 100 amp alt to convert but they are very expensive.
brightsparq ·
Anybody with one fitted got a dc clampmeter/ amp gauge? 45 amps is pretty reasonable output. Are these fitted to anything else apart from swift/ barina?
mackaymanx ·
I got 5 junk ones from my local auto electeician and when I went through the part numbers I got Yanmar, Suzuki and Diahatsu(feroza applause charade). Early '90s for the suzukis and I think the same for the diahausu stuff also.
electricmonk ·
Whoa, forgot about it being Christmas and all. Will finally have holidays in the first week of the year so will try for then
telf ·
Here's some quick ones i took tonight what a nice little unit!!!
works perfectly with every thing on EG
Lights, Wipers, Stereo with an amp the horn..... you get the piccture
Nice work mick H
mackaymanx ·
Cool, field testing is working out well.
MickH ·
telf wrote:Here's some quick ones i took tonight what a nice little unit!!!
works perfectly with every thing on EG
Lights, Wipers, Stereo with an amp the horn..... you get the piccture
Nice work mick H
No worries...mackaymanx can use my pc any time!!!!LOL...
mackaymanx ·
Number 4
scot70wagon ·
Mate are you making these to sell S I need one for my square.
mackaymanx ·
Yes I will be getting about five more of these going, depending on if the core alternators I have are usable.
telf ·
Mine is still going strong. No problems at all. Cheers
mackaymanx ·
Good to hear Telf thanks for the feedback.
mackaymanx ·
004 Paolo
005 type3lover
006 scot70wagon
007 bussboy
008 bus914
Ok that's the lot, I'll try to get in touch with everyone next week about prices etc after the school holidays.
mackaymanx ·
All spoken for.
mackaymanx ·
Just to prove I haven't be twiddling by thumbs. Just have to get the last one finished so I can test them all as a batch.
Price will be $220+postage or $200+postage if you send me a usable vw core type 1 or type 3. Don't need pulleys or fans.
mackaymanx ·
Ok, 004,006,007 and 008 are tested and running. If I can get addresses tonight I'll get them posted tomorrow.
mackaymanx ·
The alternators will have a type 2 connection on them, they come with 4 crimp terminals which gives you 2 spare for stuffups. Prise the rubber bung out the back of the plug, feed your wiring through the bung then crimp the terminals on. Then slide the terminals into the back of the plug, they will click in. The locking tab on the terminals face each other, you can see the slot from the front of the plug.Then push the bung home, the arrows line up on the back.
Ok so the link to the diagram has died so here it is again.
mackaymanx ·
Does anyone know what happened to vwombat's and electricmonk's Squarebacks? I know both of them have sold their cars, vwombat was in Mt Tamborine and electricmonk was in Adelaide. It's a bit hard to keep track of the prototypes when the cars get sold.
mackaymanx ·
Mark II
mackaymanx ·
Ok the 008 alternator is available as bus914 has not got back to me. It has been sitting in my lounge room for a month and I'm sick of it sitting there.
This will probably be the last of these rebuilt 45 amp units, as they are too much work. I may do some of the 40 amp units using a new denso core but there will be a corresponding price increase.
type3lover ·
PM sent
mackaymanx ·
Sold
008 type3lover
005 will be available later if anyone is interested as it still needs assembly.
mackaymanx ·
Ok so Saturday and Sunday was tropical rain days, so very much inside weather. This seemed like a good excuse to get on the lathe and machine up a new front housing to take the bigger double row bearing.
Managed to get some steel the other day that fitted the job prefectly, so here it is.
bus914 ·
Alt installed. Thanks Brent, works well.
bussboy ·
Thought I should follow up on the alternator which you built for me, Installation a breeze, wiring easy and a good looking item.
So 3 weeks ago I packed up the bus and did 1800km around Tasmania with no alternator problems actually no problems. 14.5 volts all the way. Many Thanks for a great product.Would recommend for any type 3 engine.
mackaymanx ·
As housings and engines pulleys can vary in dimensions sometimes, I was curious if anyone has had any pulley alignment issues. I've had no complaints but I wanted to check.
Nice pics guys, I knew that split was heavily modified but didn't know it included the engine cooling.
bussboy ·
Yep complete type 3 1600 with twin carbs, goes well but reduction hubs make top speed around 95 kmh, but mile of smiles.
Just a follow up on these, have now done over 4000 klm with one of these, never had a belt or power problem.
Picture taken 2 days ago at the Cumberland river caravan park great ocean road, Victoria
mackaymanx ·
Good to see all is going well.
Tyranicon ·
Do you sell plans or have the measurements for the units mackaymanx? I live in the USA and shipping on one of these would probably be prohibitive. I believe I could machine the parts for it using my old generator and an alternator from the parts house but I am a bit apprehensive about figuring it out and wasting my generator core without accomplishing a working solution. Any advice would be appreciated. Thank you.
mackaymanx ·
This is about the best I can do at the moment. It's not dimensioned but is to scale so you should be able to pull the dimensions off the drawing. Can't check it for you as I gone to Windows 8 and my software no longer works so I'm not able to view it myself.
Tyranicon ·
Thank you. can you remember how long the generator housing/case is after it is cut down for the assembly?
mackaymanx ·
Not offhand, I'm away from home at the moment and don't have access to my notes. Will be home by Tuesday so can have a look then.
Tyranicon ·
Thanks I would appreciate that tremendously.
Tyranicon ·
Do you think this Alt would work as a component part?
It is possible but I can't be sure just from a photo.
As long as the stator is 100mm is should be right, it has to fit into the VW generator housing which is 105mm OD.
The units I use have the 100mm OD stator and the smaller one I made has a 93mm stator OD.
Pick a unit with an electrical connector you can source easily, the end casing on the one shown is good as there are no mount lugs to remove.
clyve ·
Hi know its bbeen a while but do you still make theses and have some avalible?
Let me know as need one asap
Cheers
Sloth
mackaymanx ·
I haven't given up on these but I don't have any available or see myself getting any done in the immediate future.
Brent
clyve ·
Let me know if you do or if you can give me the details would like to have q go myself just for my type 3 cheers
bussboy ·
Just a follow up on this product now coming up 12,000 klm and still on original belt, Brent you should be proud of these, great concept and well thought out.😎
Tyranicon ·
Hello Brent,
Do you still have any of the type 3 alternators you made? or the measurements for the housing and shaft length and etcetera.
Thanks,
Bil