DIY Alternator Rebuild

[Simon_P]

Hi All,

As you may know our alternator is unique to the Elan. It does share parts with other alternators though and after a lot of searching I have found a high quality (OEM standard) distributor ie the suppliers supplier that is helpful and willing to sell me the parts.

As a note the Impulse Alternator is almost completely different, as will any replacement alternator be unless it was a reconditioned Elan unit. So If you want the correct alternator that fits it makes sense to rebuild it yourself. It isn't a difficult task and requires only minimal tools.

If you would like to rebuild your alternator see these videos:

This guy takes it apart with minimal tools:
https://www.youtube.com/watch?v=yUTd4a9f9QI
Please don't use his method of undoing the pulley nut by sticking screwdrivers through the case it is a really bad Idea.

This is a long video skip to the component tests for a clear explanation - Move the cursor until you see the meter in the shot, that's when he's explaining the test.
https://www.youtube.com/watch?v=at_R7sENE0s


I can get:
Voltage regulator the expensive bit at £20
Brush Box - the new one has a higher spring rate than the one I took out
Separate brushes if you prefer to refurb the original - requires soldering
The silicone rubber cover for the slip rings
Rubber caps - you'll see when you take it apart but they are probably ok
Bearings They are an obscure size and not readily available
The above are the bits I have identified.

The remaining parts I haven't identified - I'm willing to track them down but may need some dimensions from you to Identify the right part.
I can also get parts for other alternators.

Anyone that would like parts please let me know by the 8th August.

Alternatively I could put together a repair kit if there is any interest

[John_W]

Well done, Simon!

As my original alternator has now done 100,000 miles I reckon that investing in your proposed “repair kit” would be a good idea. I’ll take one please. Once you’ve worked out the cost let me know and I’ll send you money by cheque or paypal.

John

[JusNoGood]

Great idea. Me to please.

[simonbuk]

Sorry - a bit late to this. Having recently changed one I have a very tired looking one that smelt badly when I took it off.

I might be interested n a repair kit obviously dependent on cost.

[GeoffSmith]

Bugger! How did I miss this. If it's not too late, yes please, otherwise could you source parts relatively easily in the future?

[Tuga2112]

Simon.

given the nature of your post. may i suggest making one in the group buy section ?

i suspect theres more people like myself who have setup email alerts in the group buy section but are not keeping an eye on the engine "ancilliaries" (shouldn't that be "auxiliaries" btw) section of the forum.

i'd be interested in a full rebuild kit,
personally i prefer to get something in a box on the left of my workbench,
put the alternator on the right,
and know that by the time all the bits from the left have been swapped with something that came out of the right
i "should" have a working refurbished alternator
is the most appealing approach, specially when we are talking about a part that is particularly time consuming to remove offf the engine.

[Giniw]

I could be interested as well (depending on cost obviously)

[HJ2]

Group buy!
Count me in

[alan e]

Ok count me in to.

[Saltire]

I could be interested as well (depending on cost obviously)

I’m in too

[dapinky]

I don't actually need one, but if there is a group buy now, I'd rather have it on the shelf than have to sort it all out come the glorious day that it fails.....

[Andy_J]

Would be interested as well, although I have just put a new alternator in, I have my old one which needs a rebuild

[Simon_P]

Typical! Last time I looked there were only 2 plus me so earlier on I ordered 3 sets and a few odd bits to see if they are the right ones - the reason for the deadline was free postage to me, so John and Justin have saved a couple of quid.

I'm a bit busy at the moment so please bear with me. I'll post more details when I can.

[John_W]

(There doesn’t seem to be a “smug” smiley.)

[Rambo]

:-D

(There doesn’t seem to be a “smug” smiley.)

Isn't it this one

PS John, it's only us old farts that call the smilies anymore. Everyone else seems to call them emoji or emoticons

[Simon_P]

The first batch of bits have arrived.

The Kit will be the Voltage Regulator, Front Bearing (the bigger one), Rear Bearing and Brushbox. Price is £38.00 P+P

Other parts available:
Winding terminal insulator - Orange
Battery post insulator - Black

I'm pretty sure I can get most bits

[John_W]

Simon,
PM or email me how you want paid when you’re ready and I’ll send you my address.

Good lad!


John

[Simon_P]

You don't hang around!
List and more details here: viewtopic.php?f=4&t=27583&p=354660#p354660

[chipp]

I have an ND alternator siting on a shelf that came from my SE.
Not knowing why it failed would the contents of this kit make it useful once more.

chipp

[Simon_P]

I have an ND alternator siting on a shelf that came from my SE.
Not knowing why it failed would the contents of this kit make it useful once more.

Hi chipp, The second video in my original post shows how to test the components if they test ok then it is most likley the VR which you can't test without special equipment and is in the kit. If any fail the test give me a shout and I will try to get the replacement part.