| [ Total Views: 2120 | Total Replies: 20 | Thread Id: 110003 ] |
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 56 VDUB
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| posted on October 23rd, 2015 at 06:41 PM |
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Converting a 90mm generator to 12v
Hey there, just wondering if anybody knows where or if I can get my 90mm 6v generator converted to 12v in Aus, and what I might expect to pay to get
it done?
Cheers!
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AA003
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| posted on October 24th, 2015 at 05:52 PM |
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I am guessing that a 90mm is the standard 6v generator?
A friend of mine did this may years ago. He had to strip the windings from the armature and rewind it with two cables that had to equal half of the
cross sectional area and twice the number of windings. Many hours of labour. It can be done but would be very expensive.
I read it on samba, so it must be correct.
Sometimes Volkswagen dealers sell spare parts. Amazing isn't it!
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grumble
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| posted on October 24th, 2015 at 07:59 PM |
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Some of the industrial engines had the small diameter 12v generator like the porsche.
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psimitar
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| posted on October 25th, 2015 at 02:56 PM |
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Try an industrial motor rewinders or maybe an auto sparky would do it.
The field windings are quite simple and just wound into a round cornered rectangle that the iron core then clamps to the genny body.
The rotor winding is a little more complicated due to how the rotor is wound with multiple windings that are then soldered to the commutator contact
points 180 degrees out from each end of the winding. It's do-able but requires much patience. 
madness is in the eye of the beholder  |
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mackaymanx
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| posted on October 25th, 2015 at 05:10 PM |
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I have this if you are interested, no armature as it was so rusted I had to push it out in a press. As far as I know the coils/pole are longer in the
12 volt version.
Free as it's of no use to me. Just pay postage. Should have the end plates somewhere.
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Quote of the week
"Do I wish to send them to you again, nope, no interest can't be bothered really, to much hassle for little or no return."
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 vw54
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| posted on October 25th, 2015 at 06:03 PM |
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it used to be done quite easy but now days no auto elec would want to do it
better of finding and early Porsche genny
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56 VDUB
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| posted on October 26th, 2015 at 12:03 AM |
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Thanks for the replies!
I read that the 6v generators put out more than 12v, so you can succcessfully run a 6v generator used in conjunction with a 12v regulator, although
it won't charge the battery at idle very well, if at all, and may only last a few years before it burns out with too much use....has anyone else
heard about this? Maybe ok for a car that isn't driven a whole lot......
My second 36hp has a milled generator stand to fit a 105mm Porsche generator on it, which works great, but I want something a bit more original
looking for my old speed project motor and don't want to hack up a good original 57 block, so will have to fork out for something expensive I guess
haha!....
I guess I will look for a Porsche generator then, since thats the easiest method, shame about the lack of holes for a regulator for an original VW
look though, but I guess I can drill and tap some holes for one.... It's a shame that there aren't easier/cheaper solutions for a 36hp 
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matara
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| posted on October 26th, 2015 at 02:27 PM |
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This might help:-
http://www.allzim.com/store/zims-premium-remanufactured-generator-356-converted-to-12v.html?category_id=452
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mackaymanx
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| posted on October 26th, 2015 at 03:12 PM |
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356 are 25 amp vs industrial generator at 38 amp, depends on your needs.
Quote of the week
"Do I wish to send them to you again, nope, no interest can't be bothered really, to much hassle for little or no return."
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56 VDUB
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| posted on October 26th, 2015 at 03:49 PM |
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Thanks for the link! I can't believe how pricey though! thats nearly $900 for a generator if I incur the core charge, otherwise, I still have to send
a core over to the states, which will still be nearer $700 
| Quote: | Originally
posted by mackaymanx
356 are 25 amp vs industrial generator at 38 amp, depends on your needs.
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Yeah, that occoured to me before! the 25amp would be enough for lights? I don't use a whole lot else really, but may eventually build a small self
contained stereo off an iPhone with a second battery in parallel with the cars battery....I'm guessing that's where the issues come in with the
lower amperage right?
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psimitar
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| posted on October 26th, 2015 at 06:29 PM |
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If I had the time I'd say I'd give it a go for you as being an electrical engineer I've re-wound a few things in my time. Heck I've even got a
spare 6V genny in my stash somewhere.
Anyhoo, the idea of running a 6v with a 12v reg is a bad idea as it's running outside isn't constant delivery zone and will get pretty warm and
hence fail at some point that can be determined.
madness is in the eye of the beholder |
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Old Dubber
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| posted on October 27th, 2015 at 11:10 AM |
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This place can do it
Rapid Rewinding Pty Ltd
50 Dollis St, Rocklea QLD 4106
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56 VDUB
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| posted on October 27th, 2015 at 05:45 PM |
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| Quote: | Originally
posted by psimitar
If I had the time I'd say I'd give it a go for you as being an electrical engineer I've re-wound a few things in my time. Heck I've even got a
spare 6V genny in my stash somewhere.
Anyhoo, the idea of running a 6v with a 12v reg is a bad idea as it's running outside isn't constant delivery zone and will get pretty warm and
hence fail at some point that can be determined.
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Ahh, I wish you would haha! Theoretically, how much would you charge?
| Quote: | Originally
posted by Old Dubber
This place can do it
Rapid Rewinding Pty Ltd
50 Dollis St, Rocklea QLD 4106
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cool, have you used these guys before? they look expensive
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psimitar
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| posted on October 28th, 2015 at 03:20 PM |
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Probably $35 an hour but I'm not sure how long the rotor would take. The field windings would be about an hours work but the rotor could be 3 hrs
plus. Having not re-wound a genny I can't be more specific than that.
madness is in the eye of the beholder |
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AA003
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| posted on October 30th, 2015 at 07:41 PM |
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I doubt if you could rewind an armature in one day.
I used to do them as an apprentice many years ago.
The friend of mine that did took a few days as it was tight to get double the windings in the same space. He ended up using two conductors. I can't
remember whether he had to modify the feld coils or not.
I read it on samba, so it must be correct.
Sometimes Volkswagen dealers sell spare parts. Amazing isn't it!
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psimitar
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| posted on October 31st, 2015 at 12:01 AM |
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| Quote: | Originally
posted by AA003
I doubt if you could rewind an armature in one day.
I used to do them as an apprentice many years ago.
The friend of mine that did took a few days as it was tight to get double the windings in the same space. He ended up using two conductors. I can't
remember whether he had to modify the feld coils or not.
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As I've never done a genny before the rotor rewind time was a total guesstimate. I do know they aren't easy though.
I would hazzard that the field would need rewinding too just due to basic ohms law or you will greatly increase current and hence heat in the field
winding.
madness is in the eye of the beholder |
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AA003
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| posted on November 1st, 2015 at 03:20 PM |
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| Quote: | Originally
posted by psimitarAs I've never done a genny before the rotor rewind time was a total guesstimate. I do know they aren't easy though.
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Very hard trying to get twice the number of windings into the same space.
| Quote: | I would hazzard that
the field would need rewinding too just due to basic ohms law or you will greatly increase current and hence heat in the field winding.
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I'm just wondering if the regulator would take care of it?
I read it on samba, so it must be correct.
Sometimes Volkswagen dealers sell spare parts. Amazing isn't it!
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psimitar
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| posted on November 1st, 2015 at 04:17 PM |
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| Quote: | Originally
posted by AA003
Very hard trying to get twice the number of windings into the same space.
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True but normally with windings you either double the length or reduce the wire gauge to increase the resistance but the latter method means that
current capacity could be less.
| Quote: | Originally
posted by AA003I'm just wondering if the regulator would take care of it?
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Possibly but using dissimilar wire gauge will make the regulator work harder as the field and rotor windings magnetic field interaction would possibly
be quite different than in similar winding gauge.
Has got me thinking that I'd really like to check out how Porsche did there small body 12v genny, altho does kind of explain why the Porsche version
has a lower current output.
madness is in the eye of the beholder |
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AA003
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| posted on November 2nd, 2015 at 05:15 PM |
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| Quote: | Originally
posted by psimitar
| Quote: | Originally
posted by AA003
Very hard trying to get twice the number of windings into the same space.
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True but normally with windings you either double the length or reduce the wire gauge to increase the resistance but the latter method means that
current capacity could be less.
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Yes the wire gauge will be half of the cross sectional area which will halve the current output. The wattage will be the same.
I read it on samba, so it must be correct.
Sometimes Volkswagen dealers sell spare parts. Amazing isn't it!
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6621104
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| posted on November 24th, 2015 at 10:02 PM |
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Rewound
Did this, well paid for a 12 volt rewind for a type 3 generator, $700
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psimitar
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| posted on November 25th, 2015 at 04:52 PM |
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| Quote: | Originally
posted by 6621104
Did this, well paid for a 12 volt rewind for a type 3 generator, $700
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OUCH
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