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Update: New design front housing for our ultimate 928 alternator.
Never resting and always trying to improve 928 pieces, we redesigned our custom high output alternator's front housing:
This is the first prototype with notes written on it, by the machine shop. New custom alternator front housing.
New alternator front housing side by side with original custom housing. New alternator front housing side by side with original custom housing.
Yes, it is definitely prettier, but also more functional!
The new housing has 10.1 square inches of cooling vents, for the front windings.
The old housing has 5.5 square inches of cooling vent, for the front windings.
The increased cooling vents will allow the alternator to run much cooler, once the alternator is heat soaked, delivering even more precious voltage/amperage to keep our 928 batteries changing, when the the vehicle is subjected to higher loads.
Additionally, the new front housing is 1.25 pounds lighter and has a reduced overall diameter to make it appear closer to the stock 996/997 donor alternator.
We will also have some of the new housings clear anodized, so they will very closely match the rear housing of the 996/997 alternator.
And finally, we will be offering this housing as a separate part, for those people who have a source for a used or rebuilt 996/997 alternator, as a money saving effort for those people.
(We will still be offering complete new alternators.)
Added: And for those parts people who rationalize copying everything made because they claim that they can't buy it (Jerry feather's lover belly pan for early cars comes to mind), anyone can buy these!
Discussed a couple of changes with the machine shop. They are looking at my final detail suggestions and will get back to me.
The fixtures are done and the tooling path is programmed. Material is waiting.
The owner of the machine shop is a great, long time friend and transitioned from fixing/racing Porsches to CNC machining. (I was his crew chief in 1998 for a RSR IMSA effort.) This is a big dollar project (for both of us) and he is interested in showing his talents off.
I was wondering when these alternators would come back. The one in my 89 has served me very well since the original one failed at 210k miles.
An added perk of selling just the front housing is it makes international shipping much more economical as a full alt is definitely not something cheap to ship!
A 5 kg package insuranced from Germany to the US is ~ 50 $, I think the opposite route is nearly the same. 150 $ as a gift is custom free. Above of that you pay custom and 19 % VAT.
For EU people I would have no problem to order 10 housings from Greg, UK after the stupid Brexit is a different thing.
If something goes wrong you must drive to customs in the next city, than half a day with bureaucracy is gone so better doing big business!
Is the problem with the my 84 alternators solved?
My problem is I‘m restoring the basics on my two 928, after that I‘m open for further improvements.
Never resting and always trying to improve 928 pieces, we redesigned our custom high output alternator's front housing:
This is the first prototype with notes written on it, by the machine shop. New custom alternator front housing.
New alternator front housing side by side with original custom housing.
Someone spent some serious time on that programming and process... I've played with g-code at the "101" level and this is, well, way past "101" level!
Send me one for my 84 Euro S and I'll beta test it for you
1,400 watt stereo, HID headlights, working AC, lots of electrical add ons (auto dimming mirror, powered antenna, radar, dashcam, power door locks, etc), and gets driven everyday. Also direct voltage gauge from the battery in the ashtray area and on the 2 farad stereo capacitor to see actual voltage.
Discussed a couple of changes with the machine shop. They are looking at my final detail suggestions and will get back to me.
The fixtures are done and the tooling path is programmed. Material is waiting.
The owner of the machine shop is a great, long time friend and transitioned from fixing/racing Porsches to CNC machining. (I was his crew chief in 1998 for a RSR IMSA effort.) This is a big dollar project (for both of us) and he is interested in showing his talents off.
2 weeks?
No probs, just slide one to Mary to send me when it's ready...i'll get the lines from Kyle on...Tuesday, and will hold off.
Someone spent some serious time on that programming and process... I've played with g-code at the "101" level and this is, well, way past "101" level!
Chris Cervelli at Technodyne and his lead CNC guy is Johnny.
Chris is, quite literally, a genius (Johnny may be also, but I don't know this for a fact) and the pair of them love to think and create.
I sent them one of the original housings.
They had a used alternator.
This is what I got back...first try.
Jewelry!
If anyone, here, has an idea and needs someone to help with design and machining, I highly recommend these two!
I have one of your originals om my GTS. Worked well until it gets hot outside. Talking 100+ temps. Then the output drops (like most alternators).
If you feel this will improve output in high ambient temps then I would like one please? How much? How easy to retrofit?
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Does it have the "Do It Yourself" manual transmission, or the superior "Fully Equipped by Porsche" Automatic Transmission? George Layton March 2014
928 Owners are ".....a secret sect of quietly assured Porsche pragmatists who in near anonymity appreciate the prodigious, easy going prowess of the 928."
09-29-2023, 05:37 PM
Update: New design front housing for our ultimate 928 alternator.
George Layton March 2014