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What application crank pulley have you used...
Check here. This is what i have and it works like a charm. <!-- m --><a class="postlink" href=""></a><!-- m -->
#46 04-01-2008, 03:38 PM,
The info for an alternator that produces 60+amps and fits quite nicely is here:
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The only stupid questions are the one's that are not asked.

#47 04-01-2008, 04:07 PM,
No, I didn't get the part # just the application 89-93 Geo Metro 1liter. It is a Denso alternator. Randy is the guy I talked to.
#48 04-01-2008, 09:02 PM,
I guess I'm a newbie since this is my first post, but I've been visiting long enough to have ordered and installed the Poorboy kit on my 85 Aspy. I keep coming back to visit this subject as I too would like to charge more at lower RPMs. I have a friend who may be able to fab the pulley in the picture above, but wondered if anybody has found the 3 groove pulley in 4 or 5 inch yet. I used a Mitsubishi alt from a Metro and may have to just replace that pulley with a V-groove and use the 5 inch pulley Sundance is using. Love the kit though!
#49 06-23-2008, 12:26 PM,
Not sure myself why everyone is paranoid about the low rev charging with the external, I can sit at traffic lights idling about 1000+ with two 55 watt running lights on and still show a comfortable 12.1V at the battery.
After riding a couple of miles it is back up to 14.2
However there was a post somewhere about someone finding a 4" pulley off an Asian car but it needed drilling and a bushing made for it.
The only stupid questions are the one's that are not asked.

#50 06-23-2008, 03:55 PM,
Thanks, I guess I'm a little paranoid because while practicing slow maneuvers for my test the battery gave up and I had to push start it to get back home. I went scavenging through my local yard and found a power steering pump pulley on a 1991 Toyota 2000 16 valve motor that looked like it might be a good starting point too bad that pulley was already bent. On my mounted volt meter I have to rev about 1200 to get over 13 volts charge with just headlights on. About 1500 to get around 13 with all "chicken lights" on.
#51 06-24-2008, 04:59 AM,
I would have the battery tested.
The only stupid questions are the one's that are not asked.

#52 06-24-2008, 05:33 AM,
The battery is only 2 years old and charged immediately back up. Like I said I was idling around a parking lot in first doing slow maneuvers with the radio on and with the heat the engine fan running, using brakes as well. It hasn't died since, but I do watch the meter closely.
#53 06-24-2008, 06:04 AM,
I have my bike down for radiator repair and I'm experimenting with the smaller racing alternator I originally got for the bike. I can shoot pics now that the rad is off so I'll post new photos of the pulley setup and let you know if the smaller alt works with the new setup.
#54 06-24-2008, 06:10 AM,
As promised... pics of the large crank pulley with the tiny alternator. I'm still rebuilding, so I'll test later in the week.

These show the setup. Note that I fabricated a new lower bracket. It required 2" metal stock to get the lower mount high enough so that the alternator would reach the top bracket.

Attached Files
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#55 06-24-2008, 12:22 PM,
I am currently changing my crank pulley. I found that a Toyota Corolla power steering pump pulley is close to what I want. It measured between 3.5 to 3.75 inches. Had to use a steel rule so measurement is approx. The rear diameter of the pulley shaft hole size is close to 14mm. The front half of the pulley shaft hole is splinned and is very close to 12mm. I took the existing pulley spacer from my poorboy kit and used a drill press and file to turn down the part that sticks into the rear of pulley until it fit my new pulley. Didn't take much. I had to use one fender washer drilled out to 12mm. This placed the pulley at the same depth from the right timing cover as the original pulley from kit (.020). The crank bolt had to be changed to a 12mm x 1.25 x 60 (Grade 8.8). The belt will need to be longer. I will try to fit radiator tomorrow night. Pulley with pump - $20, new bolt - $3.50, charging at lower rpm - priceless.
#56 11-10-2008, 07:14 PM,
Any idea what year Corrolla?
#57 11-10-2008, 07:38 PM,
Sorry no I don't. I went to a junkyard near here and roamed around the parts rooms till I found a likely candidate. It is a 3 rib design.The part had no year on it.
#58 11-10-2008, 08:00 PM,
31/64th and 1/2" almost identical, and close enough, No?

is 1/32nd to much to tolerate?

I got to thinking about this and Why cuoldn't you take a 1/2" bolt that is long enough to cut the threaded part off and still be long enough to rethread a 12mm 1.25 thread pitch on it and use that to bolt a 1/2" pully bore on to the crank?
#59 02-01-2009, 07:16 PM,
Quote:I know it puts out 55 amps because I've seen it with my own eyes, although the one I have uses a lift truck rotor with more segments on the armature to give it more output at low speeds without the need for a larger crank pulley. Don't ask how much it cost because you don't want to know.

I've got to know. I am going to go with the standard poorboy pulley, but
want to avoid heating and bending the tupperware to get things to fit.
I also don't want to grind some of the case off the alternator as some of the pictures show. So paying more for the alternator might be ok. We use
electric forklifts at work, but our shop guys might help if I knew exactly what to look for.
My second choice would be the ($199) one that Sundance used.

I don't know if poorboy would sell his kit with no pulley. If I use a smaller
alternator, I'll have to make my own bracket, but the rest of the kit would be used.
A nicely cut timing belt cover might be a nice option to add to the kit.
I'm afraid I'll measure twice, then cut in the wrong spot anyway.
#60 02-07-2009, 02:14 AM,

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