Alternator conversion

[neoracer]

there are two alternators that alot of people use i think you have chosen #2, doesn't take much to cause a problem,poorboy's kit is fabbed to use the particular one i used successfully,but since you a fabbing everything from scratch you have to adapt to what your setup requires,i have the tools to make everything myself too but just simpler for me to go with the kit straight-up

[blandaw]

there are two alternators that alot of people use i think you have choice #2, doesn't take much to cause a problem,poorboy's kit is fabbed to use the particular one i used successfully,but since you a fabbing everything from scratch you have to adapt to what your setup requires,i have the tools to make everything myself too but just simpler for me to go with the kit straightup

I was kinda thinking that. I thought about the kit, but like to tinker to much and am a glutton for punishment. as long as it charges in the end, it don't matter how you get there; as long as your happy Thanks again for all the help, sure nice to have a comunity like this.

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A quick comment..I haven't been following this closely but when you go to bolt the guard back on the rad make sure you use the shortest bolts, they tend to get mixed in with the longer ones and any bolt that is a bit longer than the correct length will puncture the rad core. This has happened so many times now on these 1200s its a shame. It happened to me..I was lucky to find a good rad to replace it at the bike salvage.

BTW you won't know you've punctured it til there's a small drip of coolant catches the attention because the bolt seals the hole its made.

This is a heads up for any GL1200 owner who takes the rad guard off for whatever reason.

Now thats what I'm talkin about. Someone telling you the road is closed ahead instead of asking you in the hospital, "did'nt you know the road was closed?" Thanks for the heads up sparky65

[neoracer]

understand the "tinkering" but with 2 gl's to keep up and always doing mods to both mc's its just one thing i didn't want to "play" with,actually have another of don's kit waiting on shelf with alt waiting for the sei,whenever that decides to go south,except for color and carbs vs fi both are set up exactly the same,so actually means buying two of everything whenever a new project is thought of

funny how whenever you have spares it never seems like they are needed

[85GL1200I]

Tinkering is fine - but to me tinkering during riding season is time wasted. I figure my stator isn't going to go bad during the winter lay up, it will be some time during riding season. When the time comes, I will gladly go with Don's kit - I figure he has put a lot of time and thought into developing that into what it is.

I admire those out there that devise their own set-ups. I just don't think I would have the time or patience - knowing that I could be out riding.

Just my 3 cents worth.

[blandaw]

Tinkering is fine - but to me tinkering during riding season is time wasted. I figure my stator isn't going to go bad during the winter lay up, it will be some time during riding season. When the time comes, I will gladly go with Don's kit - I figure he has put a lot of time and thought into developing that into what it is.

I admire those out there that devise their own set-ups. I just don't think I would have the time or patience - knowing that I could be out riding.

Just my 3 cents worth.

I agree. if it where riding season, Don would have another customer. As is, my stator failed at end of season, so riding is over till spring. todays temp is 19deg.F.(wouldnt be riding today anyhow) so I have plenty of time and no other prodjects right now; so I figured why not just jump in and try this myself? Figured I'd have plenty of help here if needed and felt comfortable with doing the project. As you stated though, if I had second thoughts or time concerns, sure would hace gone with a kit!

[blandaw]

Sub zero temps and a few other projects kept me away for a few weeks, but I finaly have a little more work done. Ended up going with a 2 1/2 inch drive pully and got tired of thinking to much on the bottom radiator bolts and spacers so I just ground old ones off and welded new ones on. I used a brass collar from a brake line as a spacer behind rad. mounts. Used grinder to fit lower fairing around rad. bottom. After a good look, i will be taking more off "mud" guard for a cleaner look. Used heat gun to soften plastic and mould around alt.

[desertrefugee]

Boy, does that look familiar. Did mine a couple of years ago - and detailed the process on this site. I "wimped" out and used Don's kit. Smooth as silk and still charging away. You'll be glad you did it.

[Marty B]

Thank you for posting all those pictures. I'm not doing a poor boy conversion but I did take the whole body off the frame to have it painted. They will help me to put it back together.

[blandaw]

Boy, does that look familiar. Did mine a couple of years ago - and detailed the process on this site. I "wimped" out and used Don's kit. Smooth as silk and still charging away. You'll be glad you did it.

Looks good. Does look familiar, but mine is not that clean Nice job. I see a bracket on the engine guard; is that for feet or lights. I'm looking for mounting Ideas for a set of lights.

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Thank you for posting all those pictures. I'm not doing a poor boy conversion but I did take the whole body off the frame to have it painted. They will help me to put it back together.

Good to hear. Want to see pics when you get it back together.