Update: New design front housing for our ultimate 928 alternator.
09-30-2023, 10:49 PM
#19
Former Sponsor
Thread Starter
I do not have a cost yet, as one of my requested changes requires more material and more machine time.
One good thing is that the machining process is much more evolved and will require zero hand work, by me.
The original versions required about an hour of hand work and then needed to be tumbled, adding even more time.
Our initial thinking is that we would be able to reduce the cost of the entire alternator assembly by at least $100!
Simple to swap, once the pulley is removed. A phillips screwdriver, an 8mm socket, and a puller is all that is needed (besides tools to remove pulley.)
Last edited by GregBBRD; 09-30-2023 at 10:53 PM.
09-30-2023, 10:50 PM
#20
Former Sponsor
Thread Starter
10-01-2023, 01:23 PM
#21
So yet another part sold without proper testing from GB? Good to know the original ones won't work in Texas heat. Note to self. GB sells untested parts to unsuspecting customers. Who would have thought it? What he should be doing is send one out to everyone that fell for the 1st gen that he sold. If his parts are fully guaranteed and fully tested that shouldn't be a problem right? We shouldn't have to buy a new one to replace the defective ones we were sold on Greg's so called fantastic reputation. If you don't fix the problems you caused by selling defective parts, you are just another Carl.
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Geza (10-01-2023)
10-01-2023, 04:18 PM
#22
Rennlist Member
So yet another part sold without proper testing from GB? Good to know the original ones won't work in Texas heat. Note to self. GB sells untested parts to unsuspecting customers. Who would have thought it? What he should be doing is send one out to everyone that fell for the 1st gen that he sold. If his parts are fully guaranteed and fully tested that shouldn't be a problem right? We shouldn't have to buy a new one to replace the defective ones we were sold on Greg's so called fantastic reputation. If you don't fix the problems you caused by selling defective parts, you are just another Carl.
Other than the testing already mentioned here...what testing is missing, does it need to survive space travel?
"We shouldn't have to buy a new one to replace the defective ones"
What defective ones..is a refinement a sign of defective...?
Links to defective GB alternators?
10-01-2023, 04:34 PM
#23
Rennlist Member
I think the physics set the border, I have no problems here in north Germany with the stock alternators.
So what more can you do than putting a by Porsche tested Bosch high output alternator in a case with a lot venting slits?
So what more can you do than putting a by Porsche tested Bosch high output alternator in a case with a lot venting slits?
10-01-2023, 04:44 PM
#24
the problem is that GB in his original thread assumed that the alternator could take the heat. the venting design of the case was just a guess, and now we have another guess with no testing. and testing from buddies doesn't count when you are selling products to the public. Dr Bob in the original thread indicated that testing a heat soaked alternator mid summer wasn't fair, but I think the testing needs to be done by multiple parties since the maker self tests and has his friends test as well.
10-01-2023, 04:52 PM
#25
Rennlist Member
"So yet another part sold without proper testing from GB?"
Other than the testing already mentioned here...what testing is missing, does it need to survive space travel?
"We shouldn't have to buy a new one to replace the defective ones"
What defective ones..is a refinement a sign of defective...?
Links to defective GB alternators?
Other than the testing already mentioned here...what testing is missing, does it need to survive space travel?
"We shouldn't have to buy a new one to replace the defective ones"
What defective ones..is a refinement a sign of defective...?
Links to defective GB alternators?
Another question arises: I would be willing to bet that the original manfacturer warranty is voided the second that the case is removed. If that's the case, since the manufacturer will not provide warranty, who is providing manufacturer warranty for these alternators. What is that warranty?
10-01-2023, 04:59 PM
#26
Rennlist Member
Jeff, it doesn't need to survive space travel, but it needs to work. It makes sense that it would work, but unless it was tested, we would never know.
Another question arises: I would be willing to bet that the original manfacturer warranty is voided the second that the case is removed. If that's the case, since the manufacturer will not provide warranty, who is providing manufacturer warranty for these alternators. What is that warranty?
Another question arises: I would be willing to bet that the original manfacturer warranty is voided the second that the case is removed. If that's the case, since the manufacturer will not provide warranty, who is providing manufacturer warranty for these alternators. What is that warranty?
" it doesn't need to survive space travel, but it needs to work."
Does it NOT work?
Links?
10-01-2023, 05:06 PM
#27
Rennlist Member
10-01-2023, 05:34 PM
#28
Rennlist Member
So..you want 'testing'...it's lighter and larger windows for cooling, with less thermal mass surrounding the frontside of the unit.
What _test_ is missing? It's not a functional part of "alternator"...although it is "mount" and "body"..but it would seem to be up to that task..would probly fail a lowered chassis speed bump test.
10-01-2023, 06:16 PM
#29
Former Sponsor
Thread Starter
Improved cooling on the new alternator cover was never even discussed or thought about, in my design request to Chris Cervelli.
My request was 100% about improved cosmetics and to make my housing appear more like the rear Bosch housing.
The potential increase in cooling capacity was purely a result of this design change.
And like I told Roger, we would test to see if this helps, and advise.
All alternators suffer from voltage/amperage loss, when heat soaked. The newer style, higher output Bosch unit, is no exception to this.
As with all my products, testing was extensive...including hot weather heat soaking output. The first prototype was tested, in Arizona, in over 100 degree weather, with our fantastic A/C upgrade (read below.)
The issue with the stock alternator is that even in 90 degree weather, with all stock consumers turned on, the charging voltage will drop below 12 volts, at idle.
In our development of a 100% more efficient A/C system, we increased the current draw of the HVAC fan and added an additional condenser fan. Charging voltage dropped to way below 12 volts at idle (we saw voltages as low as 11.5 volts, with the stock alternator, commonly, when heat soaked and all consumers turned on.
The LH computers in the S4 version cars are "happier" with voltages in the 12 volt minimum range. We've seen misfires and other malfunctions at voltages below this.
My upgraded alternator solved the voltage "drop" below 12 volts, at idle, with all stock consumers on, plus my upgraded A/C system, plus a high output stereo system.
A huge improvement, over the stock alternator!
With our new front housing, we have considered that the increased cooling capacity MIGHT increase completely heat soaked, fully loaded charging output. (A change of .2 volts would be a significant change.)
As I told Roger, we will test this and advise. We will certainly need to wait until summer to do this.
In the meantime, people can purchase a lighter more pleasant appearing cover or complete alternator.
My request was 100% about improved cosmetics and to make my housing appear more like the rear Bosch housing.
The potential increase in cooling capacity was purely a result of this design change.
And like I told Roger, we would test to see if this helps, and advise.
All alternators suffer from voltage/amperage loss, when heat soaked. The newer style, higher output Bosch unit, is no exception to this.
As with all my products, testing was extensive...including hot weather heat soaking output. The first prototype was tested, in Arizona, in over 100 degree weather, with our fantastic A/C upgrade (read below.)
The issue with the stock alternator is that even in 90 degree weather, with all stock consumers turned on, the charging voltage will drop below 12 volts, at idle.
In our development of a 100% more efficient A/C system, we increased the current draw of the HVAC fan and added an additional condenser fan. Charging voltage dropped to way below 12 volts at idle (we saw voltages as low as 11.5 volts, with the stock alternator, commonly, when heat soaked and all consumers turned on.
The LH computers in the S4 version cars are "happier" with voltages in the 12 volt minimum range. We've seen misfires and other malfunctions at voltages below this.
My upgraded alternator solved the voltage "drop" below 12 volts, at idle, with all stock consumers on, plus my upgraded A/C system, plus a high output stereo system.
A huge improvement, over the stock alternator!
With our new front housing, we have considered that the increased cooling capacity MIGHT increase completely heat soaked, fully loaded charging output. (A change of .2 volts would be a significant change.)
As I told Roger, we will test this and advise. We will certainly need to wait until summer to do this.
In the meantime, people can purchase a lighter more pleasant appearing cover or complete alternator.
Last edited by GregBBRD; 10-01-2023 at 06:18 PM.