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Question about alternator, OD and manifold

To: alpines@autox.team.net
Subject: Question about alternator, OD and manifold
From: Jay_Laifman@countrywide.com
Date: Wed, 20 Nov 2002 16:18:03 -0800
On my engine with the Holbay head, the exhaust ports on the head are 
larger than stock Alpine ports.  I came across a S1/S2 type tri-Y exhaust 
headers that was actually the size of the Holbay head exhaust ports - the 
stock S1/S2 exhaust headers are NOT larger enough.  I had these 
tri-y-headers Jet Coated and installed.  The only problem was that the 
front tube was not bent enough to allow the 55 amp Hitachi alternator 
(Datsun Z) I was running.  So, I found this tiny, and I mean tiny, 35 amp 
Hitachi alternator (Mazda RX?) that fit perfectly.  It fit in the space 
and its mounting tabs lined up perfectly with the stock Alpine mount and 
with the pulleys. 

But, not all was perfect.  As soon as I did this, I found that when I was 
driving with the OD on, it would pop out once and a while - usually 
earlier in the day.  My assumption was that with the alternator pumping 
the battery, perhaps with 35 amp limit (also presumably a peak limit not a 
constant) at the limit it was fluctuating and causing issues for the relay 
that keeps the solenoid on.

So, now that I'm putting this all back together, I'm thinking of going 
back to the stock SV cast iron exhaust manifold that will allow me to put 
the larger alternator back on.  I had actually ground out the initial 
openings in the cast iron exhaust manifold to match the Holbay exhaust 
ports.  That took out the immediate step, but it still narrows down too 
far. 

It could be that this OD issue I was having had nothing to do with the 
alternator.  I'm looking for any thoughts on whether or not that makes 
sense.  Or, I should put it back as it was and track down whatever other 
problem is actually causing this OD issue.

Thanks for any thoughts.

Jay

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