Any lightweight alternator options? - MR2 Owners Club Message Board
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post #1 of 6 (permalink) Old March 18th, 2017, 20:48 Thread Starter
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Any lightweight alternator options?

The alternator on my 91 turbo needs replacing and I'd like to replace it with something better. Something lighter would be nice, but I haven't come across anything other than lightweight brackets. What about the alternator itself?

Here are the brackets I've found:
Lightweight Alternator Bracket Kit | Racer X Fabrication

Also, with the alternator out, is there anything else I should think about updating/replacing for maintenance purposes?
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post #2 of 6 (permalink) Old March 18th, 2017, 21:39
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You're not going to save much weight on an alternator, they weigh what they weigh. The bracket is an easy weight savings though if you have it out. The OEM bracket is stupid heavy, like 14 lbs. The aftermarket ones are about 2 pounds. I have the RacerX one (Although I haven't installed yet), it's a very high quality piece.
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post #3 of 6 (permalink) Old March 20th, 2017, 10:52
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I got My OEM alt bracket down to 5lbs by machining away unnecessary material. It looks like the lightweight version you can buy, just out of steel, not Al.

That's something to think about if you have access to the proper tools.
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post #4 of 6 (permalink) Old March 21st, 2017, 10:13
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Originally Posted by Chris View Post
... What about the alternator itself?
An alternator is iron and copper, and both of those are needed to meet specs. To reduce weight, you would need to reduce current rating, increase the heat load, increase the cut-in speed, or overspin it. I believe that these same compromises would apply when rewinding an existing core to higher current output.
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post #5 of 6 (permalink) Old March 21st, 2017, 12:13
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You can buy light weight pulleys for them as well
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post #6 of 6 (permalink) Old March 21st, 2017, 19:26
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Having just replaced my alternator on a gen 3 I found it difficult to find a direct replacement as Toyota have discontinued. Normally, it could simply be re-built but the rectifier and regulator were toast and replacement parts were more expensive than an aftermarket alternator which had a greater output (120 as compared to 90amps). I also have my doubts to refurbished alternators and if they actually replace these two parts which always seem to cause issues (ie diode termination cracks in mounts). My guess is that they re-solder the connections and call it good.

The reason I'm telling this story is because the replacement alternator I purchased had a slightly different spacing on the adjustment arm. This required modification to the housing so it would fit. This was a pain and after modifying I sacrificed any future warranty claims.

Moral of the story, if you want to improve the factory system spend the money on the lightweight bracket which will work with all models and buy an aftermarket replacement with a higher output (120+amps). I also think from the look of the bracket it would not interfere with removal of alternator from engine bay. This makes the whole job much easier.

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