Technical Alternator Swap Project

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Technical Alternator Swap Project

JumpJet

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So after fixing up all the little bothers with Martina while still working from home (thanks COVID), I've been in search of little projects to keep me busy. I remembered that before leaving Italy a few years ago, I purchased a Marelli alternator from a 126 and had a spare set of tin-work from my original motor, a project was born!

Since this is something that seems to be a fairly common ask, but not well documented, let's set out to remedy that. My goal is to do this as a standalone mod without tearing into Martina as she currently sits. Below I'll try to catalog my progress with pictures, gotchas, and questions. I've set no deadline, so I'll plod along as motivation and time allows.

Step 1: Basic Checks

Pulled out the tin work and alternator and did some measuring and fit checks. Based on this and some reading, the only difference are the holes for the mounting studs. The alternator mounts are 11mm further out (center-to-center) than the dynamo. Center-punched and drilled new pilot holes. Next step: drill them out, file square, and find some new bolts to fit. There is a small reinforcement strip under the dynamo bolt holes, so I may duplicate it for the wider mount or just let it ride.

Question for the masses: without spare hubs/pulley/keys to test fit, does anyone know if the dynamo parts fit on the alternator or will the alternator-specific parts pictured (bottom) from Ricambio be required?
 

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As far as I am aware., the pulley parts on the dynamo will NOT fit/align correctly on the alternator---you will require the correct alternator pulley and pully attachment to the alternator. The shims however, might fit both types of pulley.
 
I went ahead and ordered the parts from Ricambio and snagged a spare pulley, but I think I grabbed the standard dynamo pulley. Hmmmm.
The pulley boss is different because of the thicker shaft on the alternator. The two halves of the pulley are the same but fitted in reverse order.
 
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