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but were afraid to ask: 
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TR3driver
Great Pumpkin - R.I.P
Offline
I've mentioned several times that I bought an alternator for an 89 Suzuki Swift and mounted it on my TR3. I found it easy to modify the original generator pulley to fit on the alternator, with just some trimming of the area where the nut goes and a small spacer behind the pulley.
HOWEVER, the second alternator I bought for the same application; although apparently interchangeable with the first one (using the pulley that came with it), is not quite the same where the pulley mounts! The shaft is about the same length; but has an unused area at the end (with hex flats for a wrench to make it easier to R&R the big nut). The big nut also has a sort of 'skirt' around the base, making it taller. The net effect is that the part of the pulley where the shaft goes through has to be about 1/4" thinner than it was with the first one. So I trimmed a bit over 1/8" (.160" ) from the back of the pulley, and then had to relieve it a bit to avoid rubbing on the alternator housing.
On top of that, the outer edges and faces on this pulley didn't run true to the bore; so I wound up having to take truing cuts to mount it in the lathe. Instead of 10 minutes, I wound up spending the whole afternoon on it.
So, my apologies to all who have started down the same path. You'll need to either look for an aftermarket pulley to fit, or have a machine shop modify your original pulley. I would offer to machine them for you, but I'm going to be away from my shop for some time; it will likely be winter before I could get to it.
Here's a few photos of what I wound up with.
HOWEVER, the second alternator I bought for the same application; although apparently interchangeable with the first one (using the pulley that came with it), is not quite the same where the pulley mounts! The shaft is about the same length; but has an unused area at the end (with hex flats for a wrench to make it easier to R&R the big nut). The big nut also has a sort of 'skirt' around the base, making it taller. The net effect is that the part of the pulley where the shaft goes through has to be about 1/4" thinner than it was with the first one. So I trimmed a bit over 1/8" (.160" ) from the back of the pulley, and then had to relieve it a bit to avoid rubbing on the alternator housing.
On top of that, the outer edges and faces on this pulley didn't run true to the bore; so I wound up having to take truing cuts to mount it in the lathe. Instead of 10 minutes, I wound up spending the whole afternoon on it.
So, my apologies to all who have started down the same path. You'll need to either look for an aftermarket pulley to fit, or have a machine shop modify your original pulley. I would offer to machine them for you, but I'm going to be away from my shop for some time; it will likely be winter before I could get to it.
Here's a few photos of what I wound up with.
