Anyone drill out their alternator mount?

[salmostrom]

My alternator bolt backed off and ovalized both the alternator mount and the tabs on the alternator itself. I had the alternator itself drilled out and a hat bushing put in the oversize hole. I thought i was going to be able to get by with just bolting the alternator back on, but i can't get the belts to line up. I think i need to drill out the alternator mounting bracket and either use an oversize bolt or sleeve it. Has anyone done this, and, if so how the heck did you get a drill in there? I would rather not remove the radiator or front axle, but if i have to, i guess i will. Any advice would be greatly appreciated.
Cheers,
Salmo

[legionnair]

Right angle drill and not a helicoil but a thread insert

Like this:
http://www.grainger.com/Grainger/Thread ... Pid=search

Dustin

[salmostrom]

http://www.youtube.com/watch?v=3O2OxReQ ... ata_player

http://www.youtube.com/watch?v=3O2OxReQ ... ata_player

My issue is similar to the one in the video above. This guy made a great video, there is a part one that goes with it.

Just so happens right angle drills are on sale at crappy tire, so i will pick one up. I don't need the helicoil thing since i don't need the threads. Either some sort of bushing or sleeve, or maybe just an oversize bolt...

I think i might be able to get the drill in from the back side, if i move the oil lines out of the way, and possibly the transmission lines to the rad.

My big concern is lining up the drill so it is perpendicular to the belt plane, somehow winging it seems risky.

I have some pics i will post later.

Salmo

[legionnair]

Don't just drill the size you require move up in small drill incruments. The fact you are drilling a hole larger and not starting a hole this will guide you as long as you do force the drill sideways it will drill straight.

[salmostrom]

Good idea. I will do that for sure.
Crappy tire was sold out of right angle drills, must be more than one Delica in town....
I will hit the uptown crappy tire tomorrow, or get a drill from someone. I think this just might work.
Thanks for the input Legionnair!
Salmo

[Luna-Sea]

Hey,
Take some pics if you can,as
This is a not an uncommon Delica
L300 affliction.....

Right On!

[jelbon]

Beware of the angled drills. I know of several people who have been injured by them when the drill bit stalls and the drill flings itself instead. 1 broken jaw and at least one broken wrist. Try to brace the drill against a solid member and stay out of the swing. Good tools tho.

[salmostrom]

That would be all i need...a broken wrist. I saw a pic on this site someplace in my searches where the alternator smashed a guys teeth out when it fell on him. Kept thinking of that while i was wiggling that thing out of there. I pulled the drivers seat out and took the engine panel off to make life a little easier, but it is still a tight squeeze!
Got my coffee on, and am going to head out and pull the alternator off again to see about drilling this thing out.
Thanks all! So far so good.
Salmo

[salmostrom]

Hmmm, small right angle drill is still not small enough. Might work if i had extra short bits. Off to Homer Depot to see what they have for tools....
Salmo

[legionnair]

I bought 2 sets of ti coat drill bits from costco they were cheap and drill pretty good I also have no prob cutting one down with a angle grinder just remember to cool it lots when you cut them

When I did my alternator I did it from under the engine and it was not to bad about 30 min out and in.

Good luck

Dustin

[salmostrom]

Well, i got it back in and it lines up pretty good! I ended up having to wing it with the right angle drill and an attachment for tight spaces. It was kind of a frankenstein set up, but seemed to work OK. I got it mostly back together now and fired it up and there is no wobble and, while the belts aren't perfect, they line up wayyyyy better than before. I just need to get back in there and tighten the alternator belts up a bit more since i noticed the belts are a little bouncy on the bottom (how tight are they supposed to be anyway?) the way it was before, the "front belt" was really loose and the "rear belt" was tight and bouncing all over the place due to the pulley being off kilter.

Is a little bounce under there normal?

One mistake i made last night, after a bit too much wine at diner and a really long day at work was i let the negative battery connector touch the positive terminal and pretty much welded them together....i had to chase the threads after, but at least i didn't burn myself. I hope i didn't fry anything! Note to self: stick to beer.

Salmo

[nxski]

Rule of thumb with the alternator belts is that you don't want them equaling and if you twist it it shouldn't go past 90 degrees.

[salmostrom]

Got'er all back together last night and she runs like a top. No belt squeal, alternator shake or shimy, and I really can't believe how quiet the van is. I had no idea how much noise the alternator was actually making!
Thanks to all for your posts. I will get some photos up here to show you how it went and hopefully help someone out with their own problem...

This is what I found under the van originally. Original bolt was gone, somebody fabbed up a spacer (3/8 socket!) and new bolt, which surprisingly (!) came loose.

delica deer 004 resize2.jpg (184.78 KiB) Viewed 10941 times

This is the result, from the front. offset ovalizing...

delica deer 006 resize2.jpg (131.58 KiB) Viewed 10941 times

THis was my first attempt using the original spacer I found in there.

delica deer 011 resize2.jpg (156.45 KiB) Viewed 10941 times

That is all I have for photos for now, hopefully more tonight...
Cheers,
Salmo

[Leafster]

What size of bolt did you end up using? I just figured out that infernal squeaking wasn't exhaust related but a wobbly alternator mount.

Any tips on drilling the mount? Maybe a recommendation on the tool/adapter you used? Thanks, Leaf.

[Artie Fufkin]

Had exact same issue. Was busting bolts and eventually belts because alt. was at a bit of an angle.

Mount oval'ed had it drilled and a steel sleeve installed. Looked like a pain in the ass to do.

AF