Gen2 Xterra (Frontier?) - Possible alternator project

[JJBiggs]

Howdy folks...

I think it's pretty obvious of the alternator's location flaw. It's too low and I have been reading about failures due to mud contamination, etc. Lately - I have been doing some serious thinking about how to improve this situation. and...I think I have it. Here's the challenge:

- Alternator location is too low. Difficulty in relocating due to engine layout
- The Alternator is susceptible to "splashing" and "contamination" due to the location and easy access from the fender well.
- If a shroud or plate is made - air flow must be addressed to maintain consistent cooling effects

I am considering on making a "tub" of sorts that fits around the alternator. It would shield it but also provide a taller wall profile to allow the truck repeated access into a deeper pool of water, mud, etc. Taking cues from my race car days...I would also add a cooling plenum / tube with an intake position at a high pressure point near the front grill. This plenum would allow cooling air to be forced into the tub's chamber to cool the alternator.

Curious on some thoughts from the off-road guru's out there. I will post up a diagram of what I am thinking. I will also likely build a prototype to see what is possible regarding fitment.

Biggs

 

[JJBiggs]

Interestingly enough - I found a sealed 150amp alternator that is for the 4.4L BMW and Range Rover engines. Price = $240. Might be worth looking into.

Link - http://www.dbelectrical.com/p-10566...54l-bmw-540-750-x5-range-rover-1999-2009.aspx'

EDIT - scratch that. A waterjacket casing surrounds this version...more research continuing.

 

[RonapRhys]

Mean Green makes an alternator that's a decent replacement. If that's not the one, there's also one that is completely sealed and uses a connection to the water pump to stay cool.

 

[JJBiggs]

More work and research. The following are cars that have sealed alternators:

- Cadillac XTR
- Range Rover/BMW (requires custom fab'd housing)
- VW Touareg / Porsche Cayenne (possibly open on face)
- Hitachi custom unit - distributors unknown

SOLUTION - possible opportunity to fabricate a custom housing for the Range Rover / BMW 4.4L V8 sealed alternator. Results could be pricey.

Secondary solution: A serviceable alternator pan that encases the alternator with a secondary shield and pan that would allow for cooling while also providing improved protection from mud, water and debris.

Material recommended would be Aluminum sheeting. Mounting would utilize existing points on the engine and frame.

I hope to get a prototype going in the coming days.

Concept: