212 replies to this topic

[Alburglar]

I was after a small Nippon Denso alternator and some people have found them in Daihatsu Charades and such like. I took a chance on this one cod it was £12. But it's only a little bit smaller. Fail. I'll post up all the info I have so other people don't make the same mistake.

SUZUKI ALTO 2005 ( 03-06 ) 1.1 16v ALTERNATOR
TAKEN FROM A NON AIRCON MODEL
DENSO MAKE
PART NUMBER 31400-79G00 / SR102211-5610

[Alburglar]

Before my welder started buggering about, I got the gearbox mount done.


I cut off the extra support and covered the notches in the lower leg

[Alburglar]

I cut the o/s driveshaft hole bigger and then welded the seam for strength.


Ditto for the n/s driveshaft clearance.

[69k1100]

You could flip the alternator too so the body sits towards the wing. Just need custom mounts.

[Alburglar]

I'll have a look into that.

[DomCr250]

You can run it backwards and put it under the wing if you want ...thats how my swift runs its alternator

[Alburglar]

I spent just as much time fixing my welder as I did welding today, but I got a couple of bits done.
I re-inforced the front corners as planned.

[Alburglar]

And then finished off the engine mount by adding a support.

[Alburglar]

...and I think that's it, so I might even risk painting it next time.
I'll have to finish off the body work on the front end at least and hopefully start bolting stuff in, in their final positions
Body work jobs are :
Sand out the gel coat cracks on both sides of each panel and re-glass them.
Make the shut lines,where I cut off the front end nice, by re-glassing them.
I need to fix the hole I cut in the bulkhead, under the master cylinders, when I was trying to figure out clearance for the old inlet, which I've now ditched in favour of OE inlet.
...and if I remember correctly, once I'd fitted the steering rack, I wasn't 100% happy with the clearance on the drivers side gaiter, so I may have a go at that, whilst I've got the sticky stuff out.

I'm also debating on doing loads of grp on the inside roof edges and rear corners and tailgate, then sanding the horrible 'Phoenix' roof lines into something more mini estate/ van like.
But I reckon it'll add 50hours to the build.
I may just leave it and use a white carbon effect vinyl on the roof, as the old general lee vinyl made the roof look ok. I think the main car colour will be almond green....

Edited by Alburglar, 30 July 2015 - 05:09 PM.

[Alburglar]

Boxed some ends off today.

[Alburglar]

Subframe is painted.

[Alburglar]

Then I've been sanding like a loon to get ready to fibreglass stuff.
These shut lines need tarting up.



This crazing needs taking right back and reglassing.



Smoothed the inner wings of the removeable front.

[Alburglar]

I also filled the hole I cut in the bulkhead to clear the old inlet. This was a minor disaster as the bottom started to peel away, but I taped round a block of wood and used that to pin it back. I should think it will need sanding and re-doing half of it tho.

[Alburglar]

I don't know how to sand the bonnet gutters tho, asides from a thin baton of wood with sand paper round it.
Any bodywork people know a better way?

[spike 25]

Might be worth giving Stuart a call at CSG Bodyshop he knows a trick or two