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Originally Posted by alaskacruiser
Just finished rereading this thread as I'm thinking of tackling this project soon (got a bracket a while ago, just now getting around to it). I'm wondering if anyone has found a smaller-than-stock pulley to increase idle output and make the stock belts fit easier. If so, please post up! CDan- any recommendations on other Toyota pulleys that might fit the bill?
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I don't know of any Toyota pulleys but a year or so ago I had considered machining a smaller diameter pulley. It was not so much to aid in the fit of the larger alternator; but to increase the alternator rpm’s at lower engine rpm’s. I made some quick pulley groove angle gauges, did a bunch of measurements, and it can be done. This is all from memory so take it for what it is worth. If I remember correctly, the best way was to reduce the hole size where the flange nut goes in. This leaves more material that can be removed to reduce the pulley diameter. The stock pulley size can be reduced but it is taking away from the thickness that is left at the bottom of the belt grooves. Reducing the flange nut access hole size this way might require using a regular socket to remove the flange nut as opposed to an impact socket. The other thing iirc, is the maximum rpm’s that an alternator is rated at is 18000. So it probably would not be good to exceed this, especially for prolonged periods. At the time I ran some calculations from my measurements and iirc at least a 10 or 20 percent diameter reduction would not be a problem. I have the paper work and a machining drawing I started somewhere. If I find it I will post up some of the figures.
Bill