Finished alternator mounting
I finished up installing the Vans 60 amp alternator. I still need to disassembly and prime the extruded/milled aluminum parts, but everything is fitting really well. The hardest part was bending the 1/4″ strut that connects the alternator and starter. It needed a slight jog. I put it in the vise and hammered on it with a dead blow hammer until it was just right. I also had to do some more fine tuning of the mount bracket and the ears on the alternator. There was a fair amount of interference at first. The instructions say that the arm that holds the outboard side of the alternator might need a jog as well, but mine worked right out of the box.
I checked the clearance to the FAB air intake and it’s much better with the smaller alternator. The whole alternator can swing up much further before hitting the prop oil line.
I noticed one very interesting thing as I was messing withe the FAB (filtered air box). I seem to have enough room on the baffle floor to install it. I think most builders trim the outboard edge of the floor, unaware that it will cause problems fitting the FAB later on. On the advice of a couple other builders, I kept my floor full width. I’ll have to mess with it some more to be sure, but I’d be very happy if it fits without major surgery. Most builders end up modifying the FAB by cutting a chunk out of the middle, or altering the baffles.