OK that's nice work, a few questions to clear up things. how big was the hole through the pulley 1/2" or 5/8" ? put some kind of bushing in it to fit the crank bolt through? 1/2" is SOOOO CLOSE to 15/32" that the Crankshaft bolt is, I mean, what is that minuscule amount... ? did the pulley on the crankshaft need to have washers under it to space it out some from the timing belt covers, if so, ? Trial and error? The pulley important, I am trying to get everything set up/ready for WHEN (not if) the time comes and the thing goes out... as it seems to "act funny" now, per the volt gauge... I think?
the GEO Metro Alt is 55amps and the same price, refurbished on E bay. amps x volts=WATTS. stock alternator puts out 360 watts, the geo metro puts out ... 660 watts. will have to cut off the back mounting thing on the back of that alternator, just have to cover the alternator up with a trash bag/duct tape to keep cuttings out and that makes it non returnable. But IF it ever does go out, can carry new brushes on the bike, cant take but 45 minutes to put new brushes in it and or diodes. take longer to take the side cover off and alternator off than to actually fix the working parts of the alternator... or take it to the alternator shop, pay them ~$35 to clean it up, check it out, put new brushes in it. will need a HF grinder and cut off wheels anyway (~$30) for the work, cut off wheels are like $6 for 10 at HF online? Grinder ~$20, less with coupon, get 2 of them, one as a grinder and the other as a cut off wheel saw...
CHECK GRINDING/cut off wheels BEFORE EVERY USE, let it spin for a min before first application to the metal, spinning so if it flies apart, it does NOT hit anything important or SOMEONE. Femoral arteries tend to bleed out quick when hit with a broken grinding/cut off wheel/anything. safety glasses AND FACE SHIELD when grinding, I try to turn the grinder so IF it does fly apart, hopefully the parts wont hit me... in the head or the FEMORAL artery/eyes.
U removed the lower radiator mounts and bolted in all threads to get the radiator out that extra ~1"? is it 1" or is it less? still had to remove the one leg of the fan on the lower left side of the fan support? trim the leading edge of the fan a little bit and PUSH the fan a little closer to the radiator? I like the idea of drilling the crash bar for the all thread...I think? I thought the original plan was to use a piece of 1" angle iron with 2 holes drilled in it, one to mount to the motor, above the timing belts, and the other for the bolt hole to mount the bottom of the alternator? I suppose the measurement of the hole in the motor guard is... a trial and error thing, to get the alternator out past the motor just so?
a picture and MEASUREMENTS (including where the alt adjustment is to be welded on the bracket) of the upper bracket/alternator adjustment would make all the difference to us people that are seriously contemplating this modification; although, a person could probably just figure it out when they do it. have to cut out that diagonal brace and put in a piece of metal that is ... ~ 1.5" wide, ~8' long and 1/8-3/16" thick, with 2 holes in it for the 2 bolts sticking down under the fairing and then the alt adjustment slotted piece of metal is... 2" long? with 1.5" of adjustment? or is that too much. how thick is that piece? 1"... 1.5"? with the slot cut in the middle of it the size of the upper bolt of the alternator we get ~3/8-10mm, y/n?
The less that is left to CHANCE the (much) better is our success and less frustration in putting it together... and trips to the welder halfway across town. don't want to "reinvent the wheel"... too many times.
MSC INDUSTRIAL SUPPLY
Brand: TB Wood's,
Mfr Part #:
AK 4112 Item #82223306 1/2" BORE, 4" OD, 1-5/32 thickness through the bolt hole, NO KEYWAY for woodruff key (if that is important, I don't think so, if the bolt on the end of the crank is TIGHT with BLUE threadlock on clean threads) ~$14 + s/h . I think this is IT!!!! 1/2" bore is SO CLOSE to the 15/32" that I have read is the size of the hole that needs to be drilled through spacer washers put on either side of the pulley. one to space it out, just SO, and the other to hold the front of the pulley on. the thickness of that one is probably not that important. the inner one... space to fit to clear the timing belt covers... after drilling the appropriate size hole for the pulley snout in the timing covers.
or AK411 3.95" OD, $16.xx/ 5/8" bore will need to be made smaller to 15/32"
AK4178 3.95" OD, 7/8" BORE, (too big?). 1 5/32" thickness through the pulley bolt hole
BK4558 4.25 OD, 5/8" bore, 1-3/16" through bore hole (thickness thru bolt hole) $17.60