My personal favorite solution is to buy the no-name alternator at the FLAPS
for $60/70 with exchange.  They're crap, but they're crap that's guaranteed-
for-life-crap (I'm assuming they offer that lifetime guarantee because by the
time the replacement goes you'll usually be heading for a new car).  When they
start going, they're so easy to replace I just think of them as I used to
think of BIC lighters.  I generally get two to three years out of them,
although I suspect the last one I got will last forever since I'm only adding
4,000-6,000 miles a year on my '85GL.

Donald Baxter
'85 Vanagon GL
Iowa City, IA
> Well, I got my headlight relays and wiring finished last night.
> What a difference!
>   It was fairly easy once I had a game plan.
> (thanks for all the great suggestions from you folks!)
> I did end up drilling a hole up front to route wiring through.
> It just made for a cleaner, shorter wiring install than going
> all the way to the drives side and back.
>
> Anyway, while I was at it I noticed that my charging voltage
> is only about 13.1 volts. That's no good...
> I pulled the alt off so I could inspect brushes and the like, and
> found that the rear bearing is toast. Really sloppy.
> Also the slip rings are worn way down. So, I guess it's
> time for a fresh one. The FLAPS wants $140 for a rebuild. Ouch!
>
> It has occurred to me that maybe the smart thing to do is to
> replace the Bosch alt with something else...
> With a little bracket modification, I think a Ford style alternator
> could be made to fit. This would have the advantages of being
> cheaper and also using an external regulator. (I *hate* internal regs)
> With the external regulator I can connect the voltage sense lead
> to the battery, rather than sensing it alll the way back in the
> engine compartment, and get way better regulation and also be
> able to use a battery isolator to charge dual batteries. (house battery)
>
> Has anyone else here ditched their Bosch alternator for something else?
> Has anyone ever gutted the voltage regulator out of the Bosch and
> used an external regulator with it?
>
> Just curious...
>
> Steve