Alternator Rebuild Kits

did my aussie prestolite one by taking it apart.
(its a small non bird cage 2 wire alternator with 1 end of field coil grounded to case and mounting unique to my aussie motor....)

going to the bearing place and getting imperial sized bearings ordered

cleaned up the copper.

used some varnish on the edges of the case coils where it looked dubious.... presume someone had been in there before and had placed case half with coils installed, face down on a rough surface or had been "at it" with a big screwdriver rather then gently drawing the cases apart.... leave the coils in the section they are soldered into.....

used aliexpress ebay and amazon photos to identify a set of brushes with leads and springs that could be ground to fit, made my purchase. well at a few $ a go i made a few purchases and chose when they all arrived. expect 70-100K miles out of a set of decent brushes, so if worn down to stubs do the bearings as well.....

luckily.....i had no diode issues
the press fit metal diodes for mine were pretty standard and used widely. ebay had lots of similar, but i didn't need any having a decent set up in the one i rebuilt. these have anode lead cathode case or anode case and cathode lead... check em out with multimeter massive resistance 1 way little to none the other way.... 2 plates separated with thin fibreboard with material sheathed wires soldered and the diodes pressed in..... if i had had to work on it photos would have been taken....

then intsalled it and wired it all back up "Taxi/Police Pack" style with a relay switching positive 12 volts direct from battery into 12 volt in, on the regulator, to remove ammeter and bulkhead resistance from the battery charge sensing side of things. the original 12 volt feed switches the relay, the relays negative "activation coil" lead just bolted under the mounting tab to body ground.

ignition on, 12 volt across activation coil means relay on, and new battery charge sensing 12 volt, direct into regulator. had a 30 amp hella relay off a VW/Porsche in parts stash, probably overkill

works well enough... as all i had to do was replace "ware" parts

Dave