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Alternator: how would you repair this? #1382749 02/06/13 11:26 PM 02/06/13 11:26 PM
Joined: Jan 2003 Posts: 1,177 People's Republic of Kali 70runner OP super stock
70runner OP super stock Joined: Jan 2003 Posts: 1,177 People's Republic of Kali	Original date coded 3438172 alternator- a case tab (field connection) split along the brush assembly screw hole (pic, broken piece to left of tab). TIG the broken piece to the tab, fill hole and drill/tap? or? 7578266-tab.jpg (168 downloads)

Re: Alternator: how would you repair this? [Re: 70runner] #1382750 02/07/13 01:31 AM 02/07/13 01:31 AM
Joined: Jan 2011 Posts: 4,785 Utah and Alaska astjp2 master
astjp2 master Joined: Jan 2011 Posts: 4,785 Utah and Alaska	Take it to an overhaul shop and tell them you need it repaired and the necessity to keep it original. Tim 1941 Taylorcraft 1968 Charger 1994 Wrangler 1998 Wrangler 2008 Kia Rio 2017 Jetta I didn't do 4 years and 9 months of Graduate School to be called Mister!

Re: Alternator: how would you repair this? [Re: 70runner] #1382751 02/07/13 01:38 AM 02/07/13 01:38 AM
Joined: Jan 2003 Posts: 42,714 Spokane Washington ScottSmith_Harms Mr Wizzard
ScottSmith_Harms Mr Wizzard Joined: Jan 2003 Posts: 42,714 Spokane Washington	I don't know of a way to make that dissapear but you could epoxy it with something like J.B. Weld. I'd mold a blob around it filling the threaded hole and all, then when cured shape it by filing and sanding to correct shape then re-drill and tap the hole. You could also try a product called "Muggy Weld" which is a soldering rod used to repair pot metal which has a low melt temp and try the same method as above. I'd first practice either method on a spare junk core before trying it on your original.

Re: Alternator: how would you repair this? [Re: ScottSmith_Harms] #1382752 02/07/13 04:11 AM 02/07/13 04:11 AM
Joined: Jan 2003 Posts: 1,177 People's Republic of Kali 70runner OP super stock
70runner OP super stock Joined: Jan 2003 Posts: 1,177 People's Republic of Kali	Scott, actually my first thot was JB Weld, then I talked to Jim (Dixie Restos) and he suggested the TIG procedure. Says he does that on case cracks near the long bolts that attach the halves. Going to take it to a pro welder Friday to see what he says.

Re: Alternator: how would you repair this? [Re: 70runner] #1382753 02/07/13 08:05 AM 02/07/13 08:05 AM
Joined: May 2005 Posts: 4,744 Florida BDW master
BDW master Joined: May 2005 Posts: 4,744 Florida	Can the tab be replaced if you take it apart? How is it attached to the case internally?

Re: Alternator: how would you repair this? [Re: BDW] #1382754 02/07/13 11:03 AM 02/07/13 11:03 AM
Joined: Jan 2003 Posts: 9,436 Blair County,PA 62maxwgn master
62maxwgn master Joined: Jan 2003 Posts: 9,436 Blair County,PA	Quote: Can the tab be replaced if you take it apart? How is it attached to the case internally? It's not attached,it's part of the case.

Re: Alternator: how would you repair this? [Re: 70runner] #1382755 02/07/13 11:44 AM 02/07/13 11:44 AM
Joined: Jan 2003 Posts: 21,526 N.E. OHIO, USA A12 Too Many Posts
A12 Too Many Posts Joined: Jan 2003 Posts: 21,526 N.E. OHIO, USA	Silver Solder with a small metal shield under it, fill it and drill it. There's some really good silver solder out there you just have to find it.

Re: Alternator: how would you repair this? [Re: A12] #1382756 02/07/13 11:56 AM 02/07/13 11:56 AM
Joined: Jan 2003 Posts: 42,714 Spokane Washington ScottSmith_Harms Mr Wizzard
ScottSmith_Harms Mr Wizzard Joined: Jan 2003 Posts: 42,714 Spokane Washington	Tig has potential but the smaller/more delicate the repair, the more challenging and potential for disaster.

Re: Alternator: how would you repair this? [Re: A12] #1382757 02/07/13 11:59 AM 02/07/13 11:59 AM
Joined: Jan 2003 Posts: 75,070 U.S.S.A. JohnRR I Win
JohnRR I Win Joined: Jan 2003 Posts: 75,070 U.S.S.A.	Quote: Silver Solder with a small metal shield under it, fill it and drill it. There's some really good silver solder out there you just have to find it. I'd go this route , Tig is going to melt that hole thing off .

Re: Alternator: how would you repair this? [Re: JohnRR] #1382758 02/07/13 12:06 PM 02/07/13 12:06 PM
Joined: Aug 2007 Posts: 6,096 Valencia, España NachoRT74 master
NachoRT74 master Joined: Aug 2007 Posts: 6,096 Valencia, España	is the date code on back housing ? I can't recall if not, get a new housing, but I think date is on front housing... not ? With a Charger born in Chrysler assembly plant in Valencia, Venezuela

Re: Alternator: how would you repair this? [Re: NachoRT74] #1382759 02/07/13 12:08 PM 02/07/13 12:08 PM
Joined: Aug 2005 Posts: 1,294 Ontario, Canada FJ5_Fish pro stock
FJ5_Fish pro stock Joined: Aug 2005 Posts: 1,294 Ontario, Canada	There is a casting date on the housing in his pic.

Re: Alternator: how would you repair this? [Re: JohnRR] #1382760 02/07/13 12:33 PM 02/07/13 12:33 PM
Joined: Jan 2003 Posts: 9,436 Blair County,PA 62maxwgn master
62maxwgn master Joined: Jan 2003 Posts: 9,436 Blair County,PA	Quote: Quote: Silver Solder with a small metal shield under it, fill it and drill it. There's some really good silver solder out there you just have to find it. I'd go this route , Tig is going to melt that hole thing off . And you need silver solder that has the same or close to the same melting point as aluminum and the zinc content also matters.

Re: Alternator: how would you repair this? [Re: 62maxwgn] #1382761 02/07/13 12:59 PM 02/07/13 12:59 PM
Joined: Jan 2003 Posts: 21,526 N.E. OHIO, USA A12 Too Many Posts
A12 Too Many Posts Joined: Jan 2003 Posts: 21,526 N.E. OHIO, USA	Quote: Quote: Quote: Silver Solder with a small metal shield under it, fill it and drill it. There's some really good silver solder out there you just have to find it. I'd go this route , Tig is going to melt that hole thing off . And you need silver solder that has the same or close to the same melting point as aluminum and the zinc content also matters. You could make an open ended tray or mold to hold the broken piece in place and then slightly warm up the two parts. Melt the silver solder in a small cup and then pour it into the threaded hole, kind of like recasting the part.

Re: Alternator: how would you repair this? [Re: 70runner] #1382762 02/07/13 01:21 PM 02/07/13 01:21 PM
Joined: Nov 2003 Posts: 36,041 Lincoln Nebraska R RapidRobert Circle Track
RapidRobert Circle Track R Joined: Nov 2003 Posts: 36,041 Lincoln Nebraska	silver solder it as said & if that didn't work or hold up then drill/tap a new mounting hole to the right of the original broken one (closer to the base) & fab up a new brush holder/bracket that will locate the brush back in the correct original position live every 24 hour block of time like it's your last day on earth

Re: Alternator: how would you repair this? [Re: ScottSmith_Harms] #1382763 02/07/13 01:43 PM 02/07/13 01:43 PM
Joined: Sep 2012 Posts: 180 3rd rock K kloyiod
kloyiod K Joined: Sep 2012 Posts: 180 3rd rock	Quote: I don't know of a way to make that dissapear but you could epoxy it with something like J.B. Weld. Since when did J.B. Weld allow electricity to flow through it??? That's a new one on me!

Re: Alternator: how would you repair this? [Re: kloyiod] #1382764 02/07/13 02:35 PM 02/07/13 02:35 PM
Joined: Jan 2004 Posts: 27,347 Today? Who Knows? 1_WILD_RT Management Trainee
1_WILD_RT Management Trainee Joined: Jan 2004 Posts: 27,347 Today? Who Knows?	Quote: Quote: I don't know of a way to make that dissapear but you could epoxy it with something like J.B. Weld. Since when did J.B. Weld allow electricity to flow through it??? That's a new one on me! Since when does electricity need to flow through that area of a 70 & later alternator frame? FWIW I have a guy in my shop complex that tigs smaller stuff like that daily (think art), the right guy would have no problem with it... "The Armies of our ancestors were lucky, in that they were not trailed by a second army of pencil pushers."

Re: Alternator: how would you repair this? [Re: 1_WILD_RT] #1382765 02/07/13 03:14 PM 02/07/13 03:14 PM
Joined: Jan 2003 Posts: 42,714 Spokane Washington ScottSmith_Harms Mr Wizzard
ScottSmith_Harms Mr Wizzard Joined: Jan 2003 Posts: 42,714 Spokane Washington	Wild....Please ask him if he wants to do some small carb body repairas for me

Re: Alternator: how would you repair this? [Re: ScottSmith_Harms] #1382766 02/07/13 06:50 PM 02/07/13 06:50 PM
Joined: Jan 2003 Posts: 4,664 Newfoundland M mopar_man master
mopar_man master M Joined: Jan 2003 Posts: 4,664 Newfoundland	Seeing its for a 70 model car, it shouldn't be too hard to get a replacement back end .

Re: Alternator: how would you repair this? [Re: mopar_man] #1382767 02/07/13 08:31 PM 02/07/13 08:31 PM
Joined: Jan 2012 Posts: 1,650 Harm City Md. Dan Halen top fuel
Dan Halen top fuel Joined: Jan 2012 Posts: 1,650 Harm City Md.	This is just one reason I don't do the "numbers" thing anymore. God bless ya' and good luck.

Re: Alternator: how would you repair this? [Re: Dan Halen] #1382768 02/07/13 10:59 PM 02/07/13 10:59 PM
Joined: Jan 2003 Posts: 1,177 People's Republic of Kali 70runner OP super stock
70runner OP super stock Joined: Jan 2003 Posts: 1,177 People's Republic of Kali	Can someone recommend a specific brand of silver solder that would work? The rear case (with the tab) has the date code and other OE markings that I want to preserve.

Re: Alternator: how would you repair this? [Re: 70runner] #1382769 02/08/13 10:39 PM 02/08/13 10:39 PM
Joined: Feb 2005 Posts: 710 St Louis, MO 63026 convx4 super stock
convx4 super stock Joined: Feb 2005 Posts: 710 St Louis, MO 63026	TIGing on that could rune the alternator electrically. My vote is repair shop.

Re: Alternator: how would you repair this? [Re: convx4] #1382770 02/08/13 10:43 PM 02/08/13 10:43 PM
Joined: Jan 2004 Posts: 27,347 Today? Who Knows? 1_WILD_RT Management Trainee
1_WILD_RT Management Trainee Joined: Jan 2004 Posts: 27,347 Today? Who Knows?	Quote: TIGing on that could rune the alternator electrically. My vote is repair shop. Anyone that has a half a clue is gonna strip the case bare before doing any welding.... Your vote is repair shop, surprise allot of people in this thread own or work in repair shops... "The Armies of our ancestors were lucky, in that they were not trailed by a second army of pencil pushers."

Re: Alternator: how would you repair this? [Re: 70runner] #1382771 02/08/13 11:05 PM 02/08/13 11:05 PM
Joined: Jan 2003 Posts: 4,664 Newfoundland M mopar_man master
mopar_man master M Joined: Jan 2003 Posts: 4,664 Newfoundland	Quote: Can someone recommend a specific brand of silver solder that would work? The rear case (with the tab) has the date code and other OE markings that I want to preserve. Correct and theremust be hundreds still kicking around . I may have one myself for a runner vert that I parted out . if you need it and i can find it and you want to pay shipping , its yours .

Re: Alternator: how would you repair this? [Re: mopar_man] #1382772 02/09/13 02:22 AM 02/09/13 02:22 AM
Joined: Oct 2005 Posts: 8,886 Ontario, Canada S Stanton Don't question me!
Stanton Don't question me! S Joined: Oct 2005 Posts: 8,886 Ontario, Canada	Silver solder ... aluminum... really ?!?!?! You guys are speaking from actual experience, right ?!? Anyone that can tig aluminum should be able to do that in their sleep. Yeah, you're gonna hafta clean it up a bit when they're done.

Re: Alternator: how would you repair this? [Re: astjp2] #1382773 02/09/13 02:36 AM 02/09/13 02:36 AM
Joined: Aug 2003 Posts: 998 Sturgis S.D. T tripleblackcuda super stock
tripleblackcuda super stock T Joined: Aug 2003 Posts: 998 Sturgis S.D.	Quote: Take it to an overhaul shop and tell them you need it repaired and the necessity to keep it original. Tim

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