Small Alternator for Intake side of Zetec 3

[Marine7]

Fellow Seveners,

I'm at my wits end. I'm attempting to finish the assembly of my Birkin but am stumped on finding a suitable alternator. My car is fitted with a Ford Zetec3. I never liked the original alternator location below the headers, so I decided early on in the build to go with the Raceline mount. The problem is that I cant seem to find an alternator that will fit. The standard '89 Geo Metro unit that others have used with similar mounts (not Raceline) wont work because the mounting lugs are located at 12 and 6 O'clock. It appears to me that I need the smallest alternator possible (lots of tiny racing units available) but with mounting lugs located at roughly 1 and 4 O'clock. All I can find are small units with lugs at 12 and 6. I hope the attached pictures help to clarify what I'm trying to describe.

The first picture is the raceline unit with a "Valeo 45 amp unit". I found it on the Web. It's in a Cat and ont a Birkin, so I've no idea if it will fit or which Valeo part number works.

The other two photos (sorry for the size) are of my Birkin with the mount. The center photo shows the empty space with frame brace. The right photo shows a small Geo Metro Alternator. Clearly the location of the lugs make it impossible to mount with the Raceline Bracket.

Now I'm sure many of you will say "why not just call Raceline"? Well I've done that. However, they just tell me that the alternator they use is off a UK spec Escort. Obviously, they cant tell me if it'll fit the between the Ford Block and the frame brace. I'm not keen on paying for a UK spec alternator only to find out that it wont fit. Any suggestions would be very helpful.

Thanks in advance

Jason

[11Budlite]

Jason - It's hard to tell from the small photo, but is there any way you could space out the lower mount to give enough clearance to be able to use the Geo alternator with the lugs at 6 and 12 o'clock? I don't know if I've ever seen one of the really small alternators with lugs at 1 and 4.

[Marine7]

Bruce,

Sorry for the photo size. I've no idea why they posted that way.
I cant see as there is a good way to space out the lower bracket to make the Geo alternator fit. In addition to the location of the lugs, the Geo altenators lugs are not spaced properly for the bracket. Clearly the Geo option wont work.

I hate to trash the rather pricey little Raceline thingy, but am open to any other options out there. The guys who used to make brackets are all out of the business.

Thanks

Jason

[JohnCh]

It’s hard to tell from the small photo if this will work, but what if you attach the bottom to the Raceline lower mount and then replace the upper mount with a longer turnbuckle assembly? If you need something curved to clear the alternator, then how about something like this (http://www.summitracing.com/parts/SUM-G4049/?rtype=10)?

-John

[Marine7]

Hopefully this picture will be a bit better. The main culprit is finding an alternator that is both small enough and has mounting lugs that are located at 1 and 4 O'clock.

As you might be able to see, I'm trying to fit between that frame brace and the block and still be above the oil filter housting.

Thanks

Jason

[MightyMike]

Jason,

Can you have a bracket machined?

Mike

[Marine7]

Mike,

Yep, can have it machined once I find a small enough alternator. Was hoping that somebody had invented the wheel first... I have the feeling that my options are fairly limited... Figure out what the heck is out there with the correct orientation of mounting lugs or ditch this setup for a ground up build which will take more time and more money.

How is the back? Any chance you'll be able to fit up all those carbon bits soon?

Jason

[S1Steve]

Marine7, Maybe this will help give you and idea, not a birkin , on a S1. Dug out the alternator part #, Beck/Arnley #186-0600, Steve

[Marine7]

Interesting idea from the S1Steve. (I've been using the S1 build manual to help me along in my build.. very good piece of gear). However, I cant identify the lower bracket. It looks like a stock casting. I doubt I've got that much room between the side of my block and the frame brace. I might be able to use it as a starting point for mounting of a mini racing alternator in the future.

So, I bit the bullet and called the guys at Raceline. I've purchased the Valeo unit pictured in the first photo. With any luck, it'll sit close enough to the block to clear the frame brace. The Valeo unit is a new version of a Lucas alternator from UK spec Mark II escorts.

I'll post pics of the fitted unit.

Cheers

Jason

[super7guy]

I was able to machine (hand file) the stock Z3 bracket so that the Geo alt lays into it. Just one long bolt holds it in place and since it is fully supported, the belt tension ensures that it does lift up.

I too have a tight clearance on my Cat long cockpit chassis.

Wayne

[Marine7]

I've spoken to the guys at Raceline and decided to purchase their Valeo 45 amp unit. They told me it's a new unit made for an old Lucas application (hence the odd spacing of the lugs). The location of the lugs at 1 and 4 O'clock should allow a very tight fit against the block, so it "should" fit. Certainly not the cheapest of options, but this is all for fun anyway. I'll post the results when it arrives.

If it doesnt fit, maybe I'll have the first plug in hybrid Seven? Charge, drive, charge, drive...

Cheers

Jason