On-Board Air Compressor / Welder for vehicles

Step 14 Modifing the Alternator

When using a alternator without avalanche diodes you can just remove or bypass any voltage regulator and attach your power wire directly to the rotor power brush.
If your alternator has avalanche diodes like the CS-144 I'm using you must remove the diode pack and install a non-avalanche diode set.

In the CS-144 you must remove the voltage regulator and cut its connection to the brush holder, this is where we will solder out power lead. After its attached feed it out the back of the alternator case.
Now we must remove the diode pack, the diode pack is attached to a plastic frame carefully pry the diode heat sinks off it. We will be using it to hold the stator leads.

Once the diodes are removed we will crimp or solder to the stator leads three pieces of 10 gauge wire, these wire will to be fed our the back of the case where we will solder them to a diode pack from a ford 1G. If you cant solder the wires from the stator use a Transpo FR1290 diode pack your local alternator shop can order you one, this is a more heavy duty diode pack which uses screw terminals.

Now that the diode pack is attached we must re-seat the brushes:

1. First unfold a paper clip.
2. Now on the rear of the case near the bearing cup is a small hole.
3. Reach into the alternator case and push the bottom spring and brush back into its holder.
As you get the brush back in place push the paper clip into the small hole it will feed up in front of the brush holding it in place
4. Repeat this with the top brush.

You can now reinstall the rotor and upper case once its all bolted back together you can remove the paper clip.

Comments

[freddyg3753]

is the 30 amp switch grounded or does it have + power from the battery?

[rbodell]

Nothing like everything being in reach on the workbench LOL