Original Thread:
https://www.vintagefordforum.com/for...es-and-run-12v
Since I have been boasting about my 12v neg system I was told I needed to do a pictorial and text of how and what I did to get my "Alternator in a Can" or "How to fool the judges and still run 12v". So, you asked for it, and yes, I am going to get winded.
Disclaimer: There were NO working or rebuildable to working condition Powerhouse generators used in the making of this project!
First I found an old Powerhouse generator that had been in a fire, partially due to the internal parts being fried somehow. I did not get a background story on the generator, but it had this distinct smell to it when it arrived. If anyone has ever had an old electrical fire where the old style varnish had been cooked, they will know and remember that smell.
On to the meat of this. After helping out a friend by completely wiring his car (Calendar #2 April) from head to tail, I realized that the nice shiny chrome 35amp alternator he used would, or should be usable inside the Powerhouse can, and this is what got me started. So, gingerly removing the burnt intestaguts from the "can" I proceed to machine out the central cone that houses the bearings of the original stater/armature.
AiaC 5.jpg
Now, as you can see it is relatively flat on the bottom except for the radius at the very corner. If you will note, there is a ring and at that ring there are 3 holes, these are the new holes to mount the alternator. Now I did have to remove some of the ears of the alternator (voiding any warranty) to get it within the confines of the "can". You can see this in the next picture, and you can also see one of the brass spacers I made to offset the mounting so it could be straight in the "can".
AiaC 15.jpg
This next picture is the other brass spacers made to mount the other ear of the alternator. I also used nothing but flathead allen screws, if memory serves, ¼x28 on all the new screws, and whatever the slot head screw Ford used were replaces with allen. (I HATE slot top screws!!)
AiaC 11.jpg
The reason I disassembled this today is because I started with what they call a "Self Energizing" voltage regulator, which means it only needs One (1) wire to allow it to charge. Well, since hindsight is 20/20 I thought I had enough cooling but evidently I was wrong, because I let the smoke out of that regulator and had to go to my backup, which is a "tickled" or 3 wire regulator and I needed to make modifications to add the second wire from the junction box to settle down the amount of charging, and also make a setup for my backup GM alternator which is also a "tickled" regulator. And since I have the wherewithal to make it plug n play, I figured I do the tutorial at the same time.
Now, without numbing your mind, I think the following pictures should be self explaining. I am sure some of you may have questions, and you know me, chatter box as it were will be happy to answer any and all.
AiaC 8.jpg
AiaC 6.jpg
Pictured above is the sneakiest of judge foolings. If you note, there is an extra seam. Well, since the alternator is just a wee bit longer than the "can" it was necessary to add 1.375 (1 3/8") to the original "can" to allow the cover replaced to finish the charade. Now, when it is all assembled and installed in the car, the wires run right along that seam and unless you move the wires, you can't see it. You can also see the jumper across the base of the cutout since that too is no longer needed, and is covered to look stock.
The picture below you can see the three (3) new holes in the "can" to mount the alternator.
AiaC 9.jpg
If you notice, I even went to the trouble of getting the allen head screws to replace the slot screws used to hold the fields in the "can". This could be a give away to the judges, but in Touring Class I doubt they would look that closely as long as it has a generator mounted! (Your mileage may vary).
As you can see from the next picture, I used the stock feed through and soldered a 10gage wire for output from the alternator. You can also see the amount of radius left at the front of the "can".
AiaC 12.jpg
Here is the new addition to the housing for the "tickler".
AiaC 13.jpg
I went to my local electronics store and got a pair of power supply female banana feed throughs and drilled a ½" hole to pass through.
This next picture shows the amount removed from the original mounting and the 2 new threaded holes for mounting.
AiaC 14.jpg
After assembling the alternator in the "can" how the wiring is set up. You can see both wires and how they orient.
AiaC 17.jpg
AiaC 16.jpg
Just to let you see the rest of the assemblage, it is nice that the mounting ear was never welded on as I have seen so many were, and it is actually early as well with the Ford script!
AiaC 3.jpg
The altered aftermarket cover. Let us hope that there is enough flow through of air to keep the smoke inside.
AiaC 2.jpg
And the finished assemblage ready to be reinstalled. I will be running another wire through the stock harness up to the Junction box after I finish posting this.
AiaC 1.jpg
Thank you all for allowing me to ramble and use up precious minutes of your day.
Alternator 2.jpg
https://www.vintagefordforum.com/for...es-and-run-12v
Since I have been boasting about my 12v neg system I was told I needed to do a pictorial and text of how and what I did to get my "Alternator in a Can" or "How to fool the judges and still run 12v". So, you asked for it, and yes, I am going to get winded.
Disclaimer: There were NO working or rebuildable to working condition Powerhouse generators used in the making of this project!
First I found an old Powerhouse generator that had been in a fire, partially due to the internal parts being fried somehow. I did not get a background story on the generator, but it had this distinct smell to it when it arrived. If anyone has ever had an old electrical fire where the old style varnish had been cooked, they will know and remember that smell.
On to the meat of this. After helping out a friend by completely wiring his car (Calendar #2 April) from head to tail, I realized that the nice shiny chrome 35amp alternator he used would, or should be usable inside the Powerhouse can, and this is what got me started. So, gingerly removing the burnt intestaguts from the "can" I proceed to machine out the central cone that houses the bearings of the original stater/armature.
AiaC 5.jpg
Now, as you can see it is relatively flat on the bottom except for the radius at the very corner. If you will note, there is a ring and at that ring there are 3 holes, these are the new holes to mount the alternator. Now I did have to remove some of the ears of the alternator (voiding any warranty) to get it within the confines of the "can". You can see this in the next picture, and you can also see one of the brass spacers I made to offset the mounting so it could be straight in the "can".
AiaC 15.jpg
This next picture is the other brass spacers made to mount the other ear of the alternator. I also used nothing but flathead allen screws, if memory serves, ¼x28 on all the new screws, and whatever the slot head screw Ford used were replaces with allen. (I HATE slot top screws!!)
AiaC 11.jpg
The reason I disassembled this today is because I started with what they call a "Self Energizing" voltage regulator, which means it only needs One (1) wire to allow it to charge. Well, since hindsight is 20/20 I thought I had enough cooling but evidently I was wrong, because I let the smoke out of that regulator and had to go to my backup, which is a "tickled" or 3 wire regulator and I needed to make modifications to add the second wire from the junction box to settle down the amount of charging, and also make a setup for my backup GM alternator which is also a "tickled" regulator. And since I have the wherewithal to make it plug n play, I figured I do the tutorial at the same time.
Now, without numbing your mind, I think the following pictures should be self explaining. I am sure some of you may have questions, and you know me, chatter box as it were will be happy to answer any and all.
AiaC 8.jpg
AiaC 6.jpg
Pictured above is the sneakiest of judge foolings. If you note, there is an extra seam. Well, since the alternator is just a wee bit longer than the "can" it was necessary to add 1.375 (1 3/8") to the original "can" to allow the cover replaced to finish the charade. Now, when it is all assembled and installed in the car, the wires run right along that seam and unless you move the wires, you can't see it. You can also see the jumper across the base of the cutout since that too is no longer needed, and is covered to look stock.
The picture below you can see the three (3) new holes in the "can" to mount the alternator.
AiaC 9.jpg
If you notice, I even went to the trouble of getting the allen head screws to replace the slot screws used to hold the fields in the "can". This could be a give away to the judges, but in Touring Class I doubt they would look that closely as long as it has a generator mounted! (Your mileage may vary).
As you can see from the next picture, I used the stock feed through and soldered a 10gage wire for output from the alternator. You can also see the amount of radius left at the front of the "can".
AiaC 12.jpg
Here is the new addition to the housing for the "tickler".
AiaC 13.jpg
I went to my local electronics store and got a pair of power supply female banana feed throughs and drilled a ½" hole to pass through.
This next picture shows the amount removed from the original mounting and the 2 new threaded holes for mounting.
AiaC 14.jpg
After assembling the alternator in the "can" how the wiring is set up. You can see both wires and how they orient.
AiaC 17.jpg
AiaC 16.jpg
Just to let you see the rest of the assemblage, it is nice that the mounting ear was never welded on as I have seen so many were, and it is actually early as well with the Ford script!
AiaC 3.jpg
The altered aftermarket cover. Let us hope that there is enough flow through of air to keep the smoke inside.
AiaC 2.jpg
And the finished assemblage ready to be reinstalled. I will be running another wire through the stock harness up to the Junction box after I finish posting this.
AiaC 1.jpg
Thank you all for allowing me to ramble and use up precious minutes of your day.
Alternator 2.jpg
.png "thumb up")
.gif "rofl")
.png "tongue")
.png "smile")
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