alt pulley modification for TOYOTA 4AGE

[ralf]

Hello,
I swap the engine od my Europa to the TOYOTA 4AGE engine.
The 4AGE has its pulley for the alternator at the front of the engine which I don't like.
So I convert the 4AGE engine to a camshaft driven alternator pulley.

Therefor I let cast a aluminium bracket to hold an additional rollerbearing in the center if the pulley.
If you have a bearing in the center of the pulley you will not have a radial force by the V-belt to the extension of pulleyshaft.

[BDA]

Very interesting! There aren't many (any?) of us who cast our own parts! 

[ralf]

The cylinderhead and valvecover need an opening for the O-ring area of this bracket. because I dont have a big milling mashine I used a manual Hunger valveseatcutter. A guide was made to position the cutter in the center of the camshaft.

[ralf]

On my 4AGE I use a non original valve cover. With he Hunger I cut the bore in the head and the cover fixed together.

[ralf]

The finished bore looks like this.

[ralf]

At the cylinderheadside of the bracket there is diameter with an O-ring.

[ralf]

At the inner of the other side of the bracket there is a bearing hold in axial position by a ring and a seal (not at the picture)

[ralf]

The bracket is fixed at three points to the rear of the cylinderhead

[ralf]

The pulley is from a frensh 50ccm motorbike. To position the V-Belt at a level with the bearing a adaptor was made snd screwed to the pulley.

[ralf]

The conection of the pulley should be flexible. So I made a adapter which could at the one side pressed to the camshaft. At the other side a cut sproket of a Honda CB50 was fitted.

[TurboFource]

Nice work Ralf!

[jbcollier]

Very nice indeed!

[ralf]

Thanks,
the adapter is pressed to the camshaft and additionaly fixt with a 4mm pin which was fixed by a laser weld.

[ralf]

The pressed in sprocket was also fixed with three laser spots.

[ralf]

The outside of the camshaft extension is made by the shortened transmission shaft of a 1978 Honda CB50 (same shaft like the XL75/80 XR80.. which was sold in the US) and a adapter.