Make your own HIGH OUTPUT alternator! - Part 1: The Teardown!

okay so this is the start of a guide of how to modify a small case Denso hairpin op Nader to reconfigure the stator windings from a star configuration to a Delta configuration to double the output current the type of ordinary you're looking for is like this here you can generally distinguish them by the rear housing the shape of the rear housing the design of the plastic cover and also the location of the UM regulator with respect to the output stud you might find some with the regulator in a different location sometimes the stud may be pointing out of the rear as well rather than out the side of the case but the rear housing looks like this and the windings that you can see inside of it are a hairpin winding then it is a small case helping alternator however there are a few different types of stator and rotor and you need the version that's generally used in 150-160 amp alternators if you are not sure [Music] [Music] once you pulled the rear housing off you'll have access to the brush holder and then you can pull the brush holder out and double check the resistance of the riddle winding the 150 to 160 app should be 1.80 and if it's the smaller version which is only rated 400 to 130 amps and can't be modified in the same way it'll measure 2.2 ohms so this is the brush housing here the reason I choose to pull the brush has enough to measure it is because often the brushes won't make good contact and what you actually measure your meter won't be correct so once the brush housing is out there's two contacts in here and if you measure the resistance across them without spinning the alternator because that will affect the readings it should be 1 point 8 ohms so that is a 150 amp assembly or 160 M and can be modified to do 320 ohms once you're at this stage you're going to want to cut where the windings attach to the original rectifier not gonna reuse this rectifier it's not right at a high enough current so if it is cut through them about snapping your cutters off but you also want to make sure that the lead length you're keeping is long enough to go to solder it to the new rector phone well if you've got one like in front of yours and you'll see what I mean they some spot would him in such a way they can should be cut off and removed so the director flag can be replaced like replaced this data okay so there's a cup you're not fully cut through I can just cut them after or leave them off to get it out so that's fine now you want to gonna pull the right to fire off this should no longer be connected to the housing apart from by the four screws these two here and also the one through the regulator we spray your ladies not gonna be reused either because it's some possible for my application comes off like that but oh sorry now now probably gonna pull the UM case part that doesn't fit a plan as well [Music] when retightening these are going to want to go in a diagonal pattern the same as you would with a on a wheel on a car or else the case won't twist sideways and bearings will be tight you would feel it as you do it back up again probably get that if my um video actually includes the reassembly it probably the rear bearing isn't actually pressed into the rear housing but I'll often get jammed in so you will need to use a puller to actually get it out [Music] about this time that I generally engage safety squints don't know how this is gonna go so that's the rear housing with the status still stuck in it it's an eighth wonder to this stage this may separate easily the first time around or you may need to UM persuade a little bit and then just gently lever it out evenly she just pops right out like that so don't need that anymore for now and this is where the modifications happen basically this point here has three connections going to it and each one of those runs to one two and three of these windings and the other sign is the same as this point here and each one of those the opposite air and runs to one two and three so each half of this is effectively an alternator of its own what these windings are configured like is in a star configuration so each one of these center points here is a center point and then the windings run like this and then each one of these windings has diodes on it one side to ground and the other side to the positive what you do to change this to get higher current from it is reconfigure that so that instead of being in a star configuration which basically puts the one who's in series to increase the voltage at lower rpm is you change the windings to be in a Delta configuration like that that means that they are effectively in parallel rather than series so that it'll do twice the current hence 320 amp from one sixty alternator but it takes more rpm to do it so you cut the windings add some links and reconfigure it to turn that into that and that's how you get 320 apps from a 150 to 160 iPod Netta that is for another video and this is a wavy washer

Channel: Twist & Tape Technology

Views: 327,428

Keywords: Alternator, high output alternator, mechman, hairpin alternator, dc power, custom electric services, car audio, iraggi

Id: Iz1yjICoszA

Length: 9min 40sec (580 seconds)

Published: Fri Oct 12 2018

Reddit Comments

[u/firebirdude]

I've actually watched that 3 part series awhile back. He doesn't show a bench test before and after. So... hard to say what real world results he gained. If he gained 20A, was it worth the time, effort, and money? Maybe he got more, we don't know.

[u/Mhycoal]

Idk about you, but my car cost about 10k. And I have about 1k in electronics added. I’m not fucking around with anything unless I at least somewhat know what I am doing. I’m not touching that alternator for any weird mods that can potentially turn that into the most expensive, cramped sitting area ever

[u/ratrodder49]

“Engage safety squints” - must be a fan of r/Skookum