DIY 240a small case & 370a large case alternator builds

This video points out the difference between large and small case, and what's inside to make them both into high power alternators.
I'll be doing more detailed build videos sometime in the future for the diy type.

[@rebuilderinabox]

Good vid and I never say that. I love the part where you (hic) drink beer (hic) while doing the video.

[@bigdfig6083]

@2:35 "To make this quick, getting into the rectum..." WAIT! WAAAAAAAAT!!! Wow, didn't see that coming 8] Just ribbing you, bud. Good content and much appreciated.

[@georgesrisomsak9650]

LMAO

[@haydenwatson7987]

Great video. This is the first of your videos I have seen. I use an old Ample Power externally regulated alternator to charge a DIY 560Ah LFP battery bank on my sailboat. The AP alternator is 30-years old and still works fine but it was built on the old Delco DN10 case which has really bad cooling. I limit the output with an external regulator so that the case temperature is under 100ºC but that is only about 70A max. I would love to convert a modern alternator to external regulation and increase my 100% duty cycle output to between 120a and 160A. My mount uses the 20" foot typical to older GM products. Any suggestions as to a make and model of alternator to look for as a starting point to build a replacement out of? FYI, the engine is a 23hp diesel which runs most of the time at 1900 rpm.

[@georgesrisomsak9650]

If you're trying to keep the same case, this would be the place I recommend to order parts from ad rebuild your current unit with. alternatorparts.com/10dn-alternators-parts-and-kits.html I would ultimately recommend to switch to a "hair pin" denso style unit if possible, as they are MUCH more durable, have incredible output, and easy to build, modify and regulate. You're request for around 160 amps can be die with a stout small case, modified to a 240a unit as shown in the video on the red alternator. I'll see what's available that will be close to drop in, but will likely require some custom modifications for mounting and pulley type. Worth the hassle coming from a unit designed and used in 1962. Today's denso units are capable of almost 400a continuously(large case) with proper modifications, installation and use. That's about 6x your current set output.

[@haydenwatson7987]

@@georgesrisomsak9650 Thanks for the reply. My plan is to build a new alternator and keep the old one as a spare. I would like to have one that has as much output as I can reasonably get from my poor little 23-hp diesel and then use the regulator to limit it when needed for other purposes (like moving the boat) 😜. What I am hoping to do is find doner alternator from a pull-n-save wrecking yard and build from there. Can you tell me how I would identify a Denso "hair pin" style alternator.

[@georgesrisomsak9650]

@@haydenwatson7987 the stator stack, as seen in the video is the "hair pin" type, and uses square wire. The pictures of the round wire "s" style stator in the link I sent would not be the denso hairpin design. There's many benefits, the main three being power density, immense cooling. and much less noise from converting A/C to DC. Good luck on your adventure into the world of diy high power alternators! You can do it!

[@haydenwatson7987]

@@georgesrisomsak9650 Thanks. How do I go about finding the right used alternator to build my Frankenstein alt. Can you point me to a website to dig deeper. FYI, my battery is a DIY LFP pack built with 280Ah EVE cells in a 204s configuration with a JK 200A BMS and all of my cables are 2/0 so my charging limit is currently at 200A but by reconfiguring it into two 4s packs each with its own BMS I can go close to 400A charge. I had found that web site that does parts for the dn10 but would prefer to start fresh because the dn10 has almost no internal air flow and I know how hard it is to cool my current unit.

[@georgesrisomsak9650]

@@haydenwatson7987 www.amazon.com/DB-Electrical-AND0292-Alternator-Durango/dp/B007XUJ7MW This is very close to the same mounting style, but you will need to fabricate likely to install. I would recommend the "Brand X" voltage regulator, as it's the best on the market, other than some of the high end Belmar controllers, that utilize temp sense and three step charge profiles. Those can get quite spendy however. The brand x is for car audio, no temp sensing, no charge profiles to choose from. It does however provide ROCK solid voltage regulation, the best I've seen yet.

[@ShredAppalachia]

Great video. Thinking about building myself a couple. Where do you source parts if you dont mind me asking?

[@georgesrisomsak9650]

Metro alternator parts, eBay, or used from low mile new vehicles. I've found wrecked Cadillac and gm large case alts for $75, 8k miles on one 15k on the other. Brand new basically, even looked new inside and out. Especially when taken apart and cleaned up. You wouldn't.kmow the difference. What parts are you interested in? I may be able to point you in the right direction?

[@ShredAppalachia]

@@georgesrisomsak9650 I applied for an account on metro, but unsure they will accept it not having an actual business. I'd like to build a large case for a grand marquis 4.6 to start with, but the large case y mount seems harder to find.

[@georgesrisomsak9650]

@@ShredAppalachia give me the exact year, and I'll see if I can get you set up with a case for that rig.

[@p0opsy]

cool vid of your hiccups, hope it gets al; the attention your looking for

[@joeanderson1769]

i emailed you about an alternator build, but didn't hear back. I am interested in having you custom make me one for a 2007 pontiac vibe. 1.8L 4 cyl

[@georgesrisomsak9650]

@@joeanderson1769 I apologize for not getting back to you. Been crazy busy this year. I have a red 240 build sitting here ready for someone. Same alternator as the Scion TC if I'm not mistaken. Call if interested. Text first so I know who it is. 435-260-1089

[@joeanderson1769]

@@georgesrisomsak9650 glad to hear you are busy and yessir. Will reach out soon

[@bryanroupe8646]

What's your company? What would you charge to do atleast 220a rebuilt on my factory 110a good working alt in my 2012 forte ex 2.0? Do you know any factory higher amperage alt with the same mount patter or similar? Shit is be cool using a single bolt with a turn bucket if the pulley lined up. It's a beat up work car and really just need a little more electeical to get everything out of a smart3 on a single vxf.

[@georgesrisomsak9650]

I don't have a company, was entertaining the idea, but I'm going to do something different for now. Maybe I'll revisit the idea later on sometime. Unfortunately, after researching that vehicle, there are no cases made to convert to a 6 phase hairpin in that vehicle. You would be looking at a custom case, and it ain't cheap. I had the same issue with my Scion TC, but was lucky that DC power Engineering makes a billet custom case to convert it to a large case hairpin. At some point one of the big alt companies will make it happen, just a matter of time, unless it's a vehicle that is rarely used for high power 12v items like audio, winches, lights or other. What I can tell you is to do the big three and install a smaller pulley. That will make a big difference in itself for now..

[@basfro844]

Could you make a wire diagram to rewire a stock big case stator to an 370 amp stator?

[@jackmcrae3574]

How do you test a 6 phase stator

[@haydenwatson7987]

I am going to try to find a large case Denso hair pin alternator at a pull and save wrecking yard. Any ideas as to what car makes and models I should look for? It seems that they will be mostly on Honda and Toyota but when I look up specs, they seem to have the small case version. Do they typically have the power output written on the case or is a code in the part number?

[@georgesrisomsak9650]

Pretty much all vehicles use the denso "hairpin" style these days. Anything 2011 and up will likely have one. Large case units are found in all the Ford Dodge and Chevy trucks, Cadillac Ford and Chrysler SUVs and more. They are in just about every thing these days with today's high electrical demand in these newer vehicles.

[@MrMr123]

Can you do a high output alternator for a 2009 Smart Fortwo smart car 🚗🤔

[@haydenwatson7987]

If you remove the internal regulator and supply the field current from an external regulator, does it matter which ring gets the positive voltage? In other words, does the polarity of the field current matter? It would seem to me that given it is generating an AC voltage, which is then rectified by the diodes, the polarity of the rotor would not matter.

[@georgesrisomsak9650]

Absolutely correct! There's no advantage going one way or another that I've found. When I build them, I typically make the lower portion of the commutator the ground, and supply my own field to the upper ring. Just my habit, and truly doesn't matter. I would chalk it up to personal reference...

[@haydenwatson7987]

@@georgesrisomsak9650 Thanks. For my needs, I have a B-type external regulator that supplies positive field voltage with a 3-stage charge logic [bulk, absorb/time, float] and use it to charge a large 560Ah LiFePo4 battery from a small 23-hp diesel engine in my sailboat. The regulator does not have the ability to manually turn down the max field current so a large alternator would take too much power from the engine, not leaving enough to push the boat. I also have a PWM controller that I can use to pulse the voltage, which would reduce the current output, but it only pulses the negative line. My plan is to isolate both the + and - brush and connect the regulator to the + for charge control and the PWM to the - for max current limiting. With that setup, I could build a 370A large case alternator and use the full power to recharge at anchor but then be able to turn the output down to not overload the engine when I need to charge while moving the boat under power. Do you have any suggestions as to where to find a core to build this thing from? I do not live near any wrecking yards and have looked online but not found anywhere to buy old alternators to scrounge for parts.

[@happymann839]

Ausgezeichnet 👍👍👍👍👍👍👍👍👍👍👍👍👍👍👍👍

[@sophornphin6883]

[@luisdejesus7605]

Where do you get quality parts

[@georgesrisomsak9650]

Metro alternator parts, eBay(low mile wrecked new vehicle alternators). OEM alts use Japanese parts that are very reliable and second to none for reliability. I have a couple other sources that have been hit and miss. Metro is by far the best for parts, they have EVERYTHING.

[@giuseppespinale1170]

Ciao.vorrei chiederti un piccolo aiuto io ho modificato un alternatore con i magneti nel fare il test non riesco ad mettere in coppia i n 6 coppie di fili che escono dallo statore.puoi tu metter nel tuo video uno schema di come si chiudono le bobine.

[@luisdejesus7605]

Hi do you sell these builds?

[@georgesrisomsak9650]

435-260-1089 text with questions, vehicle type engine size, and your name. I can get ya taken care of!

[@jaysonyang1441]

The hiccups were funny as hell but I’m sure they were annoying you to no end 😅

[@FireKnight099]

can you help me my friend? do you have email? i build my alternator using the Twisted & Tape tutorial , but im with questions abbout it...

[@georgesrisomsak9650]

I'm at work now, but just call it's easier. 435-260-1089 Text me and I'll call or text ya as soon as I'm done with work today!

[@georgesrisomsak9650]

If you still need help, holler today. I'm off work for most of it. Just a supervisor today.

[@FireKnight099]

@@georgesrisomsak9650 i not in United states.. do you have Whatsapp ?

[@georgesrisomsak9650]

@@FireKnight099 I do not. You can email me at [e-mail], or message here and I'll do.my best to help. At work currently, but will be done here in a couple hours. Information like vehicle, a picture of the setup and the problems will make this diagnostic from another country efficient and effective. Let me know!

[@acsubnation8443]

damn hiccups hahah

[@georgesrisomsak9650]

Lol! They were bad! And stopped like 5 min after the video... 🤣