Alternator pulley
Discussion
Hi, just changed out my alternator but noticed the new pulley on the new alternator only has 6 grooves instead of 7. I had a mare of a job getting the belt off with the original alternator in position and as i have found out this was due to the old alternators pulley being too large in diameter. Now, as i cannot just swap pulleys from old alternator to new alternator due to that being wrong has anyone any ideas were i can source a correct size pulley? I have tried the usual places with no joy. Maybe someone has one I could buy. Regards Gary.
TVR Beaver said:
Try SPEND, he was making some nice Ali ones 
< This or get a garage to swap the pulleys over and this may help with the belt its certainly not hard yours being a 96 http://www.youtube.com/watch?v=kfIg2afMts8Yes you really need an impact gun to remove the pulleys...
OP I've got pulleys, probably some original ones that I've swapped for my specials if you need one. but.... I generally make them larger to reduce the load on the alternator (LR's designed for engine rpms @2500-4000 vs TVR's spinning @2000rpm higher!). Your problem is most likely fixed using a slightly longer belt, just look up the available lengths in 7PK ~ or even 6PK's (6 ribs) are used by quite a few owners (JE advises them for his brackets IIRC).
OP I've got pulleys, probably some original ones that I've swapped for my specials if you need one. but.... I generally make them larger to reduce the load on the alternator (LR's designed for engine rpms @2500-4000 vs TVR's spinning @2000rpm higher!). Your problem is most likely fixed using a slightly longer belt, just look up the available lengths in 7PK ~ or even 6PK's (6 ribs) are used by quite a few owners (JE advises them for his brackets IIRC).
spend said:
Yes you really need an impact gun to remove the pulleys...
OP I've got pulleys, probably some original ones that I've swapped for my specials if you need one. but.... I generally make them larger to reduce the load on the alternator (LR's designed for engine rpms @2500-4000 vs TVR's spinning @2000rpm higher!). Your problem is most likely fixed using a slightly longer belt, just look up the available lengths in 7PK ~ or even 6PK's (6 ribs) are used by quite a few owners (JE advises them for his brackets IIRC).
OP I've got pulleys, probably some original ones that I've swapped for my specials if you need one. but.... I generally make them larger to reduce the load on the alternator (LR's designed for engine rpms @2500-4000 vs TVR's spinning @2000rpm higher!). Your problem is most likely fixed using a slightly longer belt, just look up the available lengths in 7PK ~ or even 6PK's (6 ribs) are used by quite a few owners (JE advises them for his brackets IIRC).
I use 6 PK with a smaller Bosch alternator and a different drive ratio slower than the donar vehicle by about 10% 
Edited by Sardonicus on Monday 30th September 15:21
Yes I have the tooling to make proper rib pulleys with any number of ribs. Beware that its not as easy to cut the 40 degree grooves with the correct valley & crown radiuses as it appears, and the correct carbide tools to cut the profiles cost into the £100's!, which is why you can easily get the belt shredding syndromes..
Thanks guys. I can remove the pulley from the new alternator no problem. The alternator I removed was a wrong type bodged on by some previous owner. There was only one bolt holding it in place to give it leaverage to get the belt over the pulley, I thought at first that the tensioner pulley was on wrong but its not. Anyways the pulley of yhe old alternator is no good as its far to big. I will contact SPEND as suggested to see what can be done. The car is a 400 1995 model with serp belt and air con. All other front end pulleys are 7 grove.
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