Had this come in on the PM concerning my 60 that’s for sale (shameless plug)
So I thought it better to post the whole thing up here,
for reference I installed a second 12V alternator on my 1983 BJ60 3B, its a 160 amp Denso Brushless unit.
Don’t have the part number here at the moment but when I get back to home base in the next day or so, ill go under the hood and take a peak.
First off finding a pulley was a bit of an issue, the BJ60 I had did NOT have AC, and as a result there was no AC pulley on the crank. I had gone to Toyota and asked for one to get ordered in, they pissed around for a long LONG while, brought in the wrong part etc. etc. etc. until the flatly told me it no longer exists. So I found a pulley of the correct size, cut the mounting plate off of it, pulled the main pulley assembly off, and welded the new pulley right onto the thing. Or rather my buddy who’s an AME (aircraft maintenance engineer) welded it together. After the fact I put the whole pulley assembly on the floor of a hanger and rolled the thing a cleat 200’ in a totally straight line,
I only wish I could weld something that straight! Conversely im sure you could use a pulley off another system, however I was concerned about trying to run such a big alternator off something else, once the alternator is loaded up I didn’t want to start burning belts, RE attaching it straight to a dedicated pulley off the crank.
After that we cut and drilled a piece of plate steel to the dimensions needed to bolt into the AC mounting holes, made a hinge out of a piece of SUPER thick steel tube, ¼” wall, ¼” ID. and put a bolt through it as a pin. We then pulled a strong point off of the mounting bracket for the stock alternator and presto it was installed.
I did NOT run it though an isolator, I am relying on both the alternators regulators to manage the balancing. The one thing I have noticed in this design however is if there is no load on the system the OEM alternator regulator jumps between one and off a few times a second. But I found keeping a constant load on the system negated this issue. So just keep the fan on low or something of the sort and there are no problems. Also one less system to fail and $200 less you don’t have to spend. I have been running with this system for about 3 years now and have had zero issues.
So I thought it better to post the whole thing up here,
for reference I installed a second 12V alternator on my 1983 BJ60 3B, its a 160 amp Denso Brushless unit.
Don’t have the part number here at the moment but when I get back to home base in the next day or so, ill go under the hood and take a peak.
First off finding a pulley was a bit of an issue, the BJ60 I had did NOT have AC, and as a result there was no AC pulley on the crank. I had gone to Toyota and asked for one to get ordered in, they pissed around for a long LONG while, brought in the wrong part etc. etc. etc. until the flatly told me it no longer exists. So I found a pulley of the correct size, cut the mounting plate off of it, pulled the main pulley assembly off, and welded the new pulley right onto the thing. Or rather my buddy who’s an AME (aircraft maintenance engineer) welded it together. After the fact I put the whole pulley assembly on the floor of a hanger and rolled the thing a cleat 200’ in a totally straight line,
I only wish I could weld something that straight! Conversely im sure you could use a pulley off another system, however I was concerned about trying to run such a big alternator off something else, once the alternator is loaded up I didn’t want to start burning belts, RE attaching it straight to a dedicated pulley off the crank.After that we cut and drilled a piece of plate steel to the dimensions needed to bolt into the AC mounting holes, made a hinge out of a piece of SUPER thick steel tube, ¼” wall, ¼” ID. and put a bolt through it as a pin. We then pulled a strong point off of the mounting bracket for the stock alternator and presto it was installed.
I did NOT run it though an isolator, I am relying on both the alternators regulators to manage the balancing. The one thing I have noticed in this design however is if there is no load on the system the OEM alternator regulator jumps between one and off a few times a second. But I found keeping a constant load on the system negated this issue. So just keep the fan on low or something of the sort and there are no problems. Also one less system to fail and $200 less you don’t have to spend. I have been running with this system for about 3 years now and have had zero issues.
