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Alternator rebuild

Just thought I'd share my alternator rebuild. I'm in the process of rebuilding my '82SC engine. The alternator works fine, but it, like the rest of this engine, is a filthy oxidized mess. It needed to be disassembled and cleaned. It gave me a chance to check the bearings and brushes, too.

Here's the ugly beast before:

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'82 911SC (Complete rebuild)
Click here to go to the project website that chronicles the rebuild process
Old 02-19-2007, 04:49 PM
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These winding wires need to be de-soldered before the diode support assy can be removed.



I had a small soldering iron, so it took a little while to get them off, but eventually they released:


Here's after the diode support assy had been removed:


Then the voltage regulator/brush assy was removed:


The top casing was pulled off:


Here's it completely dissassembled:


And here's the same parts after cleaning, bead-blasting, clear-coating (the rotor and coil were only cleaned), the bearings re-packed:


Everything back together:


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'82 911SC (Complete rebuild)
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Old 02-19-2007, 04:51 PM
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Nice! I'm jealous.
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1981 911SC Wine Red
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Old 02-19-2007, 05:24 PM
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WOW!!! Is that only clear laquer sprayed on the outer casings of the alternator? Specifically, did the metal go from that mousey grey to that nice bright silver color with the help of the laquer??
#2: Are those new thru-bolts or the old ones bead blasted?
#3: What kind of a cleaning tank system and bead blasting set up is working for you??
Thanks, Bob in Plymouth,MA

Maybe I can self invite myself up to your shop to check how you are getting these great results? ;-)

Thanks! Bob
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Old 02-20-2007, 04:35 AM
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Bob,

Bead-blasting is what really does the job on tarnished parts. Although the bead-blasting gives a very nice matte finish, to prevent oxidation/tarnishing again I clear-coat with either the Dupli-color engine enamel clear coat (rated to 500F) for a glossy finish or the Dupli-color clear coat caliper spray for more of a matte finish. The alternater was sprayed with the clear engine enamel.

I have a 40gal parts washer with a water-based cleaner. I use that just to get the dirt, oil and grease off the parts.

The bolts are the original one that were bead-blasted.

Sure, come buy for a visit sometime. I'm close to Worcester. Send me an email (geoff.gerhardt@gmail.com) or pm.

Geoff
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'82 911SC (Complete rebuild)
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Last edited by squidmarks; 02-20-2007 at 11:58 AM..
Old 02-20-2007, 11:55 AM
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Wow, if the factory had ever lavished that kind of attention on the Paris-Rhones perhaps they would have had a longer service life!

Wishing you many miles and millions of coulombs of happiness.
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Old 02-20-2007, 01:15 PM
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Old 02-20-2007, 01:15 PM
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