Electrical issues

[j.hall]

I've been experiencing some electrical issues and am hoping someone can help me out.
1. New generator (Stoddards)...less than 5,000 miles.
2. New Voltage regulator (Echlin)
3. New (remanufactured) Bosch starter
4. Less than 2 year old Optima
5. All grounds and connections clean and tight.
6. New belt adjusted properly
Red indicator light came on...I disconnected the generator and drove it home. Had a friend who knows and understands auto electrical systems check it out. Could find nothing wrong....everything was putting out proper readings. Reconnected generator...red light out. After a few short drives (no more than an hour or so) red light comes back on. Same scenario. Logical assumption at this time is, red indicator light faulty? Began noticing on longer drives that starter would not work when I shut it off and tried restarting after a short period. After engine cooled it would start without any hesitation. Went for a long drive (5 hours at highway speeds), shut it off and had to push start it because of starter not working (turn key and nothing...not even a click) Tried crossing poles on solinoid and starter drive would spin but not kick out?
After about another hour of driving...smelled something hot (electrical) pulled over and the generator is smoking! BUT no red light??
I hope I explained this clearly....I'm confused as to whether the starter issue is related or is just reacting to getting heat transfer frome engine? What would cause a generator to overheat to the point of throwing solder?
Any help would be greatly appreciated...thank you in advance

joe

[j.hall]

Oops...forgot to mention...my cars a '68

[philip912]

Sounds like you have 2 separate problems. Starter & voltage regulator. I am not familar with the regulator you described. On my '68 I replaced the old Bosche with a new solid state regulator. The starter is a common problem after a long drive when it gets over heated. This is solved with a "hot start relay" that is a simple installation. There are good discussions about the hot start relay on the 912 registry BB.

[j.hall]

Thanks for your input...I will try both ideas.
The Echlin regulator is an aftermarket NAPA item...I've heard that they are not reliable....now I know.
I think my 912 was punishing me...the road trip I was taking when this happened was to look at a 911.

[philip912]

I know what it is to chase electrical problems. Whaen I completed my restoration the turn signal switch shorted and took out the wiring harness from the steering column to the fuse box! Thank God my trade experience is electrical. I built a new harness and replaced after about 80 hrs of work. I have had both problems that you discussed with regulators, generators and starter. I have a great Napa store in town but they are clueless when it comes to parts for the 912. Classic & Speed Performance in Arcadia is an excellent source if you can't find parts. I get the comment all the time from parts jockeys, "it's the same as as VW". That's when I run......... Also the 912 Registry has saved my butt with this car. I wish that they were around when I had problems in the 70's & 80's. Feel free to email me directly if you have problems because I've had them all with my '68.

[Jaems]

Also the optima can cause the generator to over heat if it is down very much. Like the car has been setting for a few weeks or there is a drain on the system. It causes the generator to over work. I have never had this problem with the optima. But other say they have. Just make sure that the optima is fully charged and you should never have this problem. I also went to an alternator instead of a generator.

Phillip is correct about the regulator. They should match the Generator and the regulator.

[j.hall]

Thanks Jaems for your Optima input...I'd never heard that before. It seems to coincide with the first generator failure...thus all the new parts I mentioned in my initial post. It was shortly after installing the Optima that it (the generator) failed although the Optima was fully charged at all times. Short of keeping a full charge on the Optima is there any other safe guard? Will a solid state voltage regulator help keep the Optima from overheating the generator?
What are you referring to with regard to "matching" the generator and regulator? My generator is the 30 amp one for later '68 912's. Did you mean the stock voltage regulator or the solid state one that Phillip mentioned? I'd like to try the solid state.

Phillip your 912 looks great! I WILL be in touch if this problem continues...hopefully this will cure it....thanks again.

joe

[philip912]

The generator and voltage regulator have to be polarized to each other so that + and - voltages match.

[j.hall]

Yes, we did polarize the new voltage regulator....is this also true of a solid state? (I'm sure there's instructions enclosed)
The more I think about it and in looking back at my paper work....these particular problems started right after installing the Optima....I remember being perplexed at that time as to why the generator went.
Philip, do you use an Optima?
Thanks a million for the advice!!

[philip912]

Nope. Don't use an Optima. Standard 22NF. I don't use rebuilt generators. Bought a brand new Bosche $105.