Ultimate High Output Bosch Alternator fits 1985-1995
12-06-2016, 06:34 PM
#31
Former Sponsor
Thread Starter
Bottom of post #1, $795 for the next month, $995 thereafter. I know enough about this project to know that between the parts cost, machine time, and the sweat equity, this is more or less a zero sum game for Greg and Hans.
I had the pleasure of testing one of these on my GTS. Here it is at warm idle, A/C on recirc, front fan on high, rear fan on three, highbeams and fogs on, Stereo on with the sharkwoofer thumping. 13.93V at the jump post:
Stock brackets, easy fitment. We had it installed in about 20 minutes.
I had the pleasure of testing one of these on my GTS. Here it is at warm idle, A/C on recirc, front fan on high, rear fan on three, highbeams and fogs on, Stereo on with the sharkwoofer thumping. 13.93V at the jump post:
Stock brackets, easy fitment. We had it installed in about 20 minutes.
For you guys sitting in front of your computer, here's the reality of doing stuff, like this:
I had to have 40 pieces made, before the CNC guy figured he could make a profit, cutting them out. I agreed and he bought enough material to make 40 pieces. Two of those pieces were "ruined" in set-up....so I ended up with 38 front housings.
At $795, I have to sell 25 completed alternators to break even....not including ANY development costs, engineering costs, drawing costs, labor to take the alternators apart and make the required modifications.
25 completed units to cover my actual cash outlay to buy the parts to do this!
My wife thinks I'm absolutely crazy, doing things like this.
I can't figure out why.
12-06-2016, 07:00 PM
#33
Archive Gatekeeper
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You know you're deep in the weeds of a project when you have to hike over to the machinist's shop to help him lift a freaking 6 foot long, 4x8 beam of aluminum onto the loading table for the CNC. Greg, what did that piece weigh? 300 pounds?
12-06-2016, 07:30 PM
#35
Nordschleife Master
Well mine is lined up.
Greg is even conscientious enough to get on phone to ask about status of power wire wires/harnesses.
In my case I had removed the little original power lines along with the wire looms for the 14 pin. Replaced any bad wire and fabricated new power lines using 1/0 quality copper cable. All were thermally and environmentally protected with materials purchased from aviation supplier. Had to do surgery at the starter attachment for the cables terminal connectors were so large.
I never lost function or had issue with everything ON, but I was never comfortable with the drop off on the voltmeter. Always knew the battery was paying for it.
I am very curious to see the new alternator.
Thanks Greg for providing such a remedy.
Greg is even conscientious enough to get on phone to ask about status of power wire wires/harnesses.
In my case I had removed the little original power lines along with the wire looms for the 14 pin. Replaced any bad wire and fabricated new power lines using 1/0 quality copper cable. All were thermally and environmentally protected with materials purchased from aviation supplier. Had to do surgery at the starter attachment for the cables terminal connectors were so large.
I never lost function or had issue with everything ON, but I was never comfortable with the drop off on the voltmeter. Always knew the battery was paying for it.
I am very curious to see the new alternator.
Thanks Greg for providing such a remedy.
12-06-2016, 07:50 PM
#36
Former Sponsor
Thread Starter
They said the chunks of aluminum were 400 lbs each.
The end product was 2 lbs.
That means they removed 18 pounds of material from each block......720 pounds of scrap. Very efficient....
In the end, he told me that the "next" batch would cost more....that he underbid the job.
Great news....
12-06-2016, 09:22 PM
#38
Archive Gatekeeper
Rennlist Member
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Here's a rear 3/4 view- the alternator has a molded backplate with two grooves to locate the business end of the FOE harness to the B+ post.
12-06-2016, 09:45 PM
#40
I sure did. and i will be bolting one on tomorrow at the shop. ill take some pictures for us early folks.
12-07-2016, 11:11 PM
#41
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The main reason being, the order of the belts, from the balencer out changed when Porsch went polyrib.
Also, one extra mounting hole on the front of the block had to be drilled and tapped. This was achieved with a right angle drill head.
12-08-2016, 01:00 AM
#42
Former Sponsor
Thread Starter
I did this upgrade on my '81S and you are correct in that the power steering pump & bracket must also be changed with the front pulley.
The main reason being, the order of the belts, from the balencer out changed when Porsch went polyrib.
Also, one extra mounting hole on the front of the block had to be drilled and tapped. This was achieved with a right angle drill head.
The main reason being, the order of the belts, from the balencer out changed when Porsch went polyrib.
Also, one extra mounting hole on the front of the block had to be drilled and tapped. This was achieved with a right angle drill head.
Porsche didn't go to a 6 rib belt because they got bored.
Pretty unlikely a "V" belt will drive a 100 amp alternator....much less a 150 amp unit.
12-09-2016, 12:10 PM
#44
Former Sponsor
Thread Starter
Pretty amazing response to this product, Thanks to all that have ordered or are contemplating ordering!
As long as Bosch doesn't run out of new alternators for me to modify and I dont get more than 38 orders (the number of front housings i had produced), I can ship within a few days.
The first 10 orders will ship today/Monday/Tuesday, depending on Mary's ability to process the orders. I should have 10 more ready to ship by the middle of next week. Not all of those are currently spoken for.
As long as Bosch doesn't run out of new alternators for me to modify and I dont get more than 38 orders (the number of front housings i had produced), I can ship within a few days.
The first 10 orders will ship today/Monday/Tuesday, depending on Mary's ability to process the orders. I should have 10 more ready to ship by the middle of next week. Not all of those are currently spoken for.
