---------- Forwarded message ----------
From: Roger Whittaker <rogerwhitt1@gmail.com>
Date: Sun, Mar 11, 2012 at 10:53 PM
Subject: photos of alternator repair
To: Vanagon <vanagon@gerry.vanagon.com>, Wetwesties <
wetwesties@yahoogroups.com>

dear fellow vanagoniterites

had a failure of bracket bolts that holds the alternator on
these are 3 vphotos of the post failure - post repair
https://plus.google.com/u/0/photos/116828846299053554075/albums/5718875672406204625

repairs were made without disturbing the coolant pipe and without damage to
the precious O ring

my friend suggested we use a tap to re thread the more than 1/2 inch of
hole left from the failure ...
we cold see that the previous attempt to repair had only been half heart-ed
as the helicoil had only been placed into the first 3/8 inch of the socket
...
we wasted a tap > cut it shorter to fit in behind the coolant pipe and
after first tap we cut the bottom to crete a bottoming tap to gain every
thread we could in the socket which had been compromised so badly by
helicoil/block failure>
the port bolt had been twisted off inside the socket and left only about
one thread turn available ...which is to say useless

> i ordered the bracket from gowesty that is determined to be the fix (ya
ya i could have done this or that ... but we required a pre engineered
starting point)
my mentor decreared that he was surprised at how light the piece was ...
wished it had been a little heavier  except when we were bending it a
little after the welds to allow fitting >

> to allow me to put my fingers in to tighten the nut on the newly fixed
stud we ground off some of the meat from the OEM bracket directly over the
stud >

then he choose a piece from his scrap pile and we fitted and fixed that in
place and drilled a hole into the flange on the port side of the broken
port bolt
this was welded to the OEM bracket which was also welded to the newly fixed
bracket from go westy

we also had to remove some of the meat from the "gusset" that runs along
the bottom of the OEM bracket

once in place the alternator was replaced and seconds later after a
tightening of the belt the vanagon was purring in fine vanagon form

Back on the road again :)

regards

--
roger w
 From Proverbs:
Under three things the earth trembles, under four it cannot bear up: a
servant who becomes king ...
----------------------------------------------------------
Explore printed work at: http://www.prliving.ca/
View the growing list of video work at:
http://www.youtube.com/user/LastonLastof#g/u
http://www.prpeak.com/articles/2010/11/29/multimedia/video/doc4c62e5f80d228504902172.txt

--
roger w
 From Proverbs:
Under three things the earth trembles, under four it cannot bear up: a
servant who becomes king ...
----------------------------------------------------------
Explore printed work at: http://www.prliving.ca/
View the growing list of video work at:
http://www.youtube.com/user/LastonLastof#g/u
http://www.prpeak.com/articles/2010/11/29/multimedia/video/doc4c62e5f80d228504902172.txt