Please print, complete and return a Liability Statement with all orders. These are available for printing at the Liability Statement Page.
Thank you for your order. Your support makes possible further research and development on the Corvair.
Revision: 11-9-10. These Instructions supersede all previously dated or undated Instruction Sheets.
Thank you for buying an Alternator Bracket. Your purchase makes possible my further research and development on the Corvair. In this way, you’re investing in the future development and perfection of your chosen motor.
These notes are supplementary to my most current Conversion Manual. This Alternator Bracket is developed as part of the system that we use to convert aircraft motors. This system is outlined in the Conversion Manual. The parts alone, without the information contained in the Manual, will not allow you to develop as reliable an aircraft conversion. When I develop and market a part, it is fully flight tested, and designed to work in concert with the other parts in the conversion. I take into account the way that most people are capable of installing and operating the part. There’s a great deal of consideration that goes into these issues, and I urge you to utilize all the information in the Manual and the parts in the way that they are intended to be used. Of course, contact me at any time with any question you may have.
To be fair, everyone needs to understand that these are not certified parts, and it's not a certified motor. Experimental is not a misnomer; everything we do in this field is of increased risk. If anyone even suspects that they have a problem, E-MAIL or CALL ME. If you have never worked with torque wrenches and precision fasteners, get help from an A&P. Let's all remember to use our heads and not take unnecessary risks. I have gone to great lengths to make these components as reliable and easy to install as possible within the bounds of affordability. I have personally flown all of these parts, because I have a low opinion of people who market aircraft parts without flying the parts themselves. I believe that each and every part I sell is the best solution to its respective aspect of converting a Corvair engine. Take your time and do good work. The system is proven and will reward you with the same type of reliable flight performance we have always had.
This Front Alternator Bracket design is the third one we’ve used on Corvair powered aircraft, and by far and away, is the best of them all. It has been flying on our
aircraft and a number of others for several years. It is light and strong, and has a perfect track record. Additionally, the bracket is supported off the front cover and
only stabilized off the cylinder head. This keeps the belt tension constant throughout expansion and contraction cycles of the engine, which in rare circumstances tended
to loosen the hardware on earlier designs.
The appropriate alternator part number for the bracket is in the Conversion Manual. The smaller bracket is mounted on the two 3/8” bolts in the 8 and 10 o’clock positions
on the front cover as you face the engine. It may be necessary to file the front cover flat in this area to allow the bracket to sit stably. This mounting must take place
before the Prop Hub, Front Alternator Pulley and Ring Gear are permanently mounted. The main bracket mounts behind the small one. The slotted adjustment hole is on top.
This bracket is not drilled for the AN-3 mounting holes because each engine requires a custom fit. The outboard section of the bracket has one ¼” hole in it. This hole
is for a bolt which will go through a spacer and stabilize the bracket to the cylinder head. The distance from this hole to the centerline of the engine varies on Corvair
engines depending on gasket thickness, head style, machining, etc. On 1966-69 cylinder heads, these holes will be 5/16”. Simply drill out the bracket to 5/16” for these
heads. Mount the main bracket on the cylinder head and allow it to float back and forth. By placing your alternator on the main bracket, you can align the alternator’s
pulley with the drive pulley on the engine. With the belt as a guide, align the bracket perpendicular with the crankshaft. A spacer or shim may be required between the
main bracket and the smaller one attached to the front cover. This generally varies from 60/1000” to .187” thick. When it is aligned, C-clamp it in place, then remove
the Hub and Ring Gear, and drill the shim and main bracket for the three 3/16” holes already piloted in the smaller bracket. Secure this with AN-3 bolts and all-metal
locknuts. You can now permanently install the Hub, Puck, Ring Gear, etc. The bolts on the cylinder head will require spacers to hold the alternator bracket stable on
the outer end. A small piece of tubing on each one, trimmed square, does a nice job. Grade 8 hardware store bolts with lock washers under the heads are acceptable for
the outboard bolts.
Numerous photos of this installation in progress can be viewed on the 601 pages of our Web site at www.FlyCorvair.com/601Sep2004.html.