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Sarah's Personal Cruiser
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Date:  5-21-2015
Number of Hours:  10.00
Manual Reference:  FlyCorvair Manual
Brief Description:  Rear Alternator Design 1

With plans to have full exterior and interior lighting along with electric cabin heat there was the need for a more capable alternator than is typically used with the Corvair. With guidance from WW I cloned an early rear alternator design that he had briefly marketed and adapted it to be manufactured with the limited shop capabilities I had available. The alternator selected was the PowerMaster 8182 75 Amp ND alternator. This alternator requires a high drive speed to produce its rated output so the smallest available pulley was used on the alternator itself and the largerst possible drive pulley was developed using COTS products for the critical part. The pulley is based on a GM alternator drive pulley mounted to a Phenolic like material spacer, all of this mated to the end of the Harmonic Balancer on the aft end of the engine. This could be done more simply if one had access to a metal forming lath and large stock to produce a single piece from aluminum. The original FlyCorvair part was such a single piece and I had a part to use for reference but it has a diameter that is too small to be suitable for my use. Following some of the technique used by Mark Langford on his own rear alternator I came up with an easy to manufacture design for a lower attach bracket. The upper attach will allow for belt tensioning and will be more complicated. That parts design is being postponed until the drive pulley is in place and a lower bracket made and installed so the final location of the alternator can be determined.
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PowerMaster 75 Amp ND Alternator

PowerMaster 75 Amp ND Alternator

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Drive Pulley and Spacer

Drive Pulley and Spacer

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Lower Alternator Attach Bracket

Lower Alternator Attach Bracket

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