914/6 alternator change out., Replace alternator. Options

[914Toy]

As most of you know, removing/installing an alternator in our 6's without dropping the engine is a challenge, due to the engine firewall and fan shroud minimum access configuration. I have accomplished this in the past with the aid of a good sized hatch in the firewall - even so, it was still a challenge.

My alternator failed (probably voltage regulator problem) on the way to the recent "Unstock event". Fortunately Pelican Parts suggested I return this 175 amp (WASP) alternator under warranty (installed a year ago) for full value replacement with a new one. The high amp is to accommodate the electric AC i have installed in my car.

It took a couple of weeks to complete return and delivery of the alternators. During this time started by the challenge of removing the used alternator, I decided to research and make modifications to the fan shroud to accommodate an easier exchange of the alternator. I did not find much in my research, so i proceeded to modify the fibre glass shroud cover to give access to the alternator. The following pics show what I did, and after a test run proved as successful.


Shows where I cut (Dremel with thin cutting wheel) the fibre glass shroud.

Shows the piece removed.



Shows the strips of thin aluminum sheet riveted to both sides of the shroud piece, with a 1/4" overlap to sandwich the large remaining shroud edge in place.


Shows access to the alternator and it's wiring before returning the now removable piece of shroud for such access.


Finished installation.

This was worth the effort, which greatly reduced the challenge of remove/replace alternators in our 914/6's.

[johnhora]

I admire your fortitude and determination....it's not the easiest task with the engine out...heck just to get that cut on the shroud is amazing.
Very cool!

[mlindner]

That is a great idea 914Toy, I'm sure down the road I'll be doing that. Love it. Mark

[roblav1]

Why can't you remove the entire fan shroud? 12 carb nuts, throttle, and fuel disconnect sure seems easier than cutting the shroud.

[Luke M]

Why can't you remove the entire fan shroud? 12 carb nuts, throttle, and fuel disconnect sure seems easier than cutting the shroud.

It's a big PIA either way. For us that have done this in the car know how much of a pain it is. Yeah you could pull the whole upper end off and remove the shroud with the alt housing. I for one would rather just drop the engine. I can have the engine on the ground and alt off by the time you would have the fan housing ready to come off.
Been there, done that so I know which is faster. If you look at the 3.6 shrouds it looks similar to what 914toy did to his. Nice job..

[jim_hoyland]

Nice Keith (IMG:style_emoticons/default/smile.gif)

[ClayPerrine]

There is a thread in the classics forum that tells how to change an alternator on a /6 with the engine in the car.

http://www.914world.com/bbs2/index.php?showtopic=10187

It is not hard to do.

Clay

[forrestkhaag]

I'm still looking for the fan shroud on my car..............
It must be in theere somewhere.....

(IMG:style_emoticons/default/beerchug.gif)

[Steve]

I'm still looking for the fan shroud on my car..............
It must be in theere somewhere.....

(IMG:style_emoticons/default/beerchug.gif)

I think its up front behind the radiator!! (IMG:style_emoticons/default/beerchug.gif)

[rgalla9146]

I'm with Luke and Clay.
It's not fun either way but in the end you get satifaction from a correct job.
I also get to look around and catch other things that can be better or need
attention.
In thirty seven years and a few 914 6s I've only needed to do this job
twice.
We're gluttons I guess.
The OPs solution is very clever and well done (IMG:style_emoticons/default/thumb3d.gif)

[rgalla9146]

As most of you know, removing/installing an alternator in our 6's without dropping the engine is a challenge, due to the engine firewall and fan shroud minimum access configuration. I have accomplished this in the past with the aid of a good sized hatch in the firewall - even so, it was still a challenge.

My alternator failed (probably voltage regulator problem) on the way to the recent "Unstock event". Fortunately Pelican Parts suggested I return this 175 amp (WASP) alternator under warranty (installed a year ago) for full value replacement with a new one. The high amp is to accommodate the electric AC i have installed in my car.

It took a couple of weeks to complete return and delivery of the alternators. During this time started by the challenge of removing the used alternator, I decided to research and make modifications to the fan shroud to accommodate an easier exchange of the alternator. I did not find much in my research, so i proceeded to modify the fibre glass shroud cover to give access to the alternator. The following pics show what I did, and after a test run proved as successful.


Shows where I cut (Dremel with thin cutting wheel) the fibre glass shroud.

Shows the piece removed.



Shows the strips of thin aluminum sheet riveted to both sides of the shroud piece, with a 1/4" overlap to sandwich the large remaining shroud edge in place.


Shows access to the alternator and it's wiring before returning the now removable piece of shroud for such access.


Finished installation.

This was worth the effort, which greatly reduced the challenge of remove/replace alternators in our 914/6's.

Hey Keith
Please tell us about your carburator plumbing....looks like a great solution
to another early 911 / 914 6 quirky issue.

[914Toy]

I have Tangerine's plumbing through the tunnel into the engine bay, and up through the tin on the passenger side. Then I had a local hose shop make flexible high pressure hose to a fuel filter, on to a pressure regulator, and then on to the carbs, all with pressure hose end fittings. Given low pressure for carbs (3lb/in sq.) pressure fittings are not needed, but are safer and user friendly when removing and installing this equipment. The metal plumbing on the carbs was supplied by a local fellow.

[rgalla9146]

I have Tangerine's plumbing through the tunnel into the engine bay, and up through the tin on the passenger side. Then I had a local hose shop make flexible high pressure hose to a fuel filter, on to a pressure regulator, and then on to the carbs, all with pressure hose end fittings. Given low pressure for carbs (3lb/in sq.) pressure fittings are not needed, but are safer and user friendly when removing and installing this equipment. The metal plumbing on the carbs was supplied by a local fellow.

The sweated banjos on the carbs are neat and easy solution to the often leaky
(and clunky) connecting hose and clamps. Another unique idea.... well done !