470 alternator conversion kit, a season later

[natemoore]

I finally had to replace the power steering lines, but while I was rooting around the engine I noticed a couple problems with the alternator, which I installed last year from a conversion kit.

Metal fatigue caused the lug on the primary wire to break off (no wonder the #1 battery died a couple weekends ago). I made a new, super-duty lug using a piece of 1/4" soft copper tubing since I couldn't find a suitable lug at my auto parts places.

After putting everything back together, I noticed the black wire that goes to the + side of the coil was hanging on by a thread. Okay, taking it apart again

What is this big black chunk of plastic that the red and black wires come out of? I wouldn't even know what to ask for at a parts place. Are there any electronics inside of it? I've got good McGruber skills, but I'm not sure I can fix this one.

Thanks.

 

[natemoore]

Re: 470 alternator conversion kit, a season later

Has this stumped everyone? I hate having to drop $100 over a frayed wire.

 

[natemoore]

Re: 470 alternator conversion kit, a season later

Okay, I measured the resistance between the terminals and corresponding wires. Since it's jumping around, I'm assuming there are some electrical components inside. So, I don't want to blindly take a dremmel tool to it. The black wire goes to the + side of the coil. The red wire goes to the same place as the big red primary wire: starter solenoid terminal.

I found an alternator that looks identical to mine, except the the black plastic thing on the back doesn't have the two wires like mine does. It only has one wire.

If I knew the purpose of my "black box" with the two wires, or even what the part is called, I'd be able to start searching for a replacement part.

Any ideas?

 

[Don S]

Re: 470 alternator conversion kit, a season later

I don't know what it's called, but if you take the alternator off and take it to an alternator/starter repair facility, I'm sure they can tell you.

 

[natemoore]

Re: 470 alternator conversion kit, a season later

Since I'm apparently blazing a trail, I'll post my findings. I know there are a lot of 470s out there with these aftermarket conversion kits.

The part is a 2-wire connector with integrated spark arrestor for marine use. It is for a Delco Type 10SI alternator. The WAI Global part number is 46-1805. Delco part number is 1988381. I found a company selling these for $1.95, but they had a $25 minimum order amount, plus $21 S&H. I also found them on ebay for $12 with $5 S&H. I ordered the latter.

I'm going to use my Dremmel tool with ball mill end to remove some of the plastic from the stubby wire in an attempt to solder it. Really need to get the family out on the water tomorrow. It's almost June and we've only been out once! That's pathetic.

 

[Don S]

Re: 470 alternator conversion kit, a season later

Does your alternator vibrate a lot? Common problem I have found in several kits. Brackets and brake have broken.. What you might want to try after you get your new part is to tie the wires down to the alternator so that everything vibrates at the same time.

 

[natemoore]

Re: 470 alternator conversion kit, a season later

Does your alternator vibrate a lot? Common problem I have found in several kits. Brackets and brake have broken.. What you might want to try after you get your new part is to tie the wires down to the alternator so that everything vibrates at the same time.

I suppose it does because I found one of the mounting bolts broken?!?! It came with the kit, but it wasn't automotive grade. I replaced it with a Grade 8 and I will do what you suggested. Thanks.

 

[guyaverage]

Re: 470 alternator conversion kit, a season later

My bracket setup is homemade, but I too was snapping bolts, even grade 8. Had to add a small support bracket (from the adjustment bracket down to the water pump housing) in an effort to triangulate the support. It seems to have worked, havent snapped one since, but for a while there they were shearing right off at the head like clockwork. Weird, considering the alternator on my nephews Crownline with a 5.0 vibrates so bad at idle, its nothing but a blur, and thats the factory setup. Go figure....

 

[natemoore]

Re: 470 alternator conversion kit, a season later

My bracket setup is homemade, but I too was snapping bolts, even grade 8. Had to add a small support bracket (from the adjustment bracket down to the water pump housing) in an effort to triangulate the support. It seems to have worked, havent snapped one since, but for a while there they were shearing right off at the head like clockwork. Weird, considering the alternator on my nephews Crownline with a 5.0 vibrates so bad at idle, its nothing but a blur, and thats the factory setup. Go figure....

One of the long, skinny bolts holding the two halves of the alternator together also broke in two.