Author Topic: alternator plunger project  (Read 883 times)

Offline edboy

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Re: alternator plunger project
« Reply #15 on: 28.07. 2020 00:14 »
hi kiwi  thanks for suggestions. i m waiting to rebuild bottom end and then sort out sprockets and chain line before taking on the outer cover. a belt drive would solve oil issues but i want to fit a clutch shock absorber. i take your point about the 3  front screws which are in the wrong place so may seal up the cover permanently and cut a large clutch access hole like an ariel. the outer cover does present a problem as i want an oil bath, a primary breather ,a stator lead cable and clutch and rotor cutouts.

Offline edboy

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Re: alternator plunger project
« Reply #16 on: 06.08. 2020 23:33 »
the photos show where i m at with the alternator project.
going for the triumph duplex clutch was major problems. the chainwheel was too large . the standard plunger chainwheel needed a 2mm cut to fit the triumph centre outer race and all the clutch plates now have to be machined to fit. the standard bsa plunger clutch would fit  exactly but thre would be no shock absorber.
the triumph duplex engine sprocket was one tooth larger so the chain needed one extra link. however i fitted the sprocket back to front against a later bevelled spacer with oil seal and the chain lined up perfectly.
still lots of work to do but check out photos for general idea.

Online muskrat

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Re: alternator plunger project
« Reply #17 on: 07.08. 2020 01:20 »
Clever little vegimite. Fun re-designing things isn't it?
Cheers
'51 A7 plunger, '57 A7SS now A10CR,  '83 CB1100F, 88 FXST .
Australia
Muskys Plunger A7

Offline RDfella

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Re: alternator plunger project
« Reply #18 on: 07.08. 2020 10:17 »
No way out of fitting that cranked link?  They are at best 75% as strong as a normal link. I've had so many fail I refuse to use them now.
'49 B31, '49 M21, '53 DOT, '58 Flash, '00 Firestorm, Weslake sprint bike.

Offline edboy

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Re: alternator plunger project
« Reply #19 on: 08.08. 2020 12:22 »
i agree about the cranked link . but the chain was too taught without it. i think after a  few thousand miles the chain will stretch a little and i can swop it  for a strait link.

Online chaterlea25

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Re: alternator plunger project
« Reply #20 on: 08.08. 2020 14:07 »
Hi edboy
You could consider using the front alternator mounting studs to secure the primary case as on late triumphs ?

John
1961 Super Rocket
1963 RGS (ongoing)

Offline edboy

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Re: alternator plunger project
« Reply #21 on: 21.10. 2020 02:11 »
finally got some charging from the alternator.
had a few setbacks on the way. the last one was i fitted a duff stator .
the cover looks horrible as the cost of ally welding would be too high. i m thinking of making a spacer plate for a std cover to make room for the alternator without any welding.
still need to cut clutch plates but using  std plunger clutch without shock absorber like late notruns for now.
i will post pictures later but bare in mind tiny budget because i m on pay reduction and lockdown.

Offline RDfella

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Re: alternator plunger project
« Reply #22 on: 21.10. 2020 12:24 »
Sort out the outer cover the way you want it with lots of filler etc. Finish off to a spot-on finish then use as a plug to make a grp mould from which you make your new grp outer primary cover. Not as much work as it sounds - basically what I did for my project's primary cover.
'49 B31, '49 M21, '53 DOT, '58 Flash, '00 Firestorm, Weslake sprint bike.

Offline Blackcat

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Re: alternator plunger project
« Reply #23 on: 23.10. 2020 12:33 »
Hi!

Someone ( I think in Thailand) did an alternator conversion to a plunger A7 before. All I have is this photo. I’ve got lots more A10/A7 alternator pics including several home made conversions if anybody is interested.

My own newly restored alternator A10 (see attached photo) is complete enough to go for a test ride (covid and weather permitting) this weekend.

Regards

Martin

Online chaterlea25

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Re: alternator plunger project
« Reply #24 on: 23.10. 2020 20:47 »
Hi Martin,
Its not clear from your photo but are you using A or B type primary cases on your A10 ?

John
1961 Super Rocket
1963 RGS (ongoing)

Offline edboy

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Re: alternator plunger project
« Reply #25 on: 23.10. 2020 21:18 »
hi martin,
the main problem is making an outer cover. yours looks neat so what did you use? and any close ups?