Sunbeam Talbot Ten - Dynamo Alternator upgrade & Dynamator pulley shenanigans

As part of the upgrade to the head lamps it was clear we need a bit more power than the Dynamo could provide.  The Lucas C45 unit comes complete with fan to cool the engine, the bearings were in need of replacement. 

A couple of C45 Alternator upgrades are available, a cheaper option which is the Dynamator or a more expensive option. I've read the 2 units are different inside and one is made to a price point. They both retain the look of an original Dynamo which I wanted and the relative ease of mounting using existing brackets it seemed the easy choice. It doesn't come with a cooling fan so we also upgraded to an electric fan and mechanical thermostat. (see different post)

Wiring is easy with a 6mm cable to the battery and a single wire to the ignition light on the dash. It provides 40A, not a high valve compared to modern cars but covers what we need. 

Samuel turned some spacers from 16mm Aluminium bar stock to replace the washers used when aligning.

Crank Pulley

The Crank pulley was out of shape and we tried to straighten the best we can. It is a pressed steel affair which is brazed onto a mounting boss that fits on the crankshaft. I did look a re-manufacturing, again the Rootes Archive Trust came up trumps with the drawings but I can't justify the cost and unsure if I could sell a small batch to recover costs. 

The original crank pulley on the Ten is roughly based on an a SPB profile belt. On buying the car a previous owner had fitted a SPA belt which did the job but the wear rate was high as it didn't fit correctly. Dave Bamforth sourced the correct belt but with the change to the Dynamator a different length belt was required.

.

Image copyright - www.bearing-king.co.uk/

Image copyright - www.bearing-king.co.uk/

Dynamator Pulley Machining

The Dynamator pulley is fitted with a SPA belt profile which doesn't match the crank pulley. That leaves running the SPA belt and suffer excessive wear or machine the Dynamator pulley to match the Crank pulley. 

Not the easiest to machine and on our small Myford not the easiest to hold in the chuck. Using a ground down boring bar we could make the necessary 20 degree cut to remove enough material. Both SPA & SPB profiles have a 40 degree profile.

 

Sunbeam Talbot Ten - Temperature Gauge

 An advantage of the Hillman Minx Cast Iron cylinder head is a pocket to take a capillary temperature gauge. The gauge will be mounted under the dashboard. 

CBS - Durite 52mm Temperature Gauge

Sunbeam Talbot Ten - Front Indicator & Trafficator Upgrade

 The car was fitted with additional front indicators. Again they had used Halogen spot light bulbs which was totally overkill power wise and being mounted on the front bumper the cables were on show.

The new head lamps are fitted with side lamp which frees up the original front side light to be used as an indicator.  As part of the re-wire the Trafficators are back. 

Sunbeam Talbot Ten - Custom Fuel Funnel

 Frivolous, quite likely but who cares. Filling the tank via a funnel is tricky as you need 1 hand to hold the funnel and another 2 to hold the jerry can. Not any more!

Custom designed for the Sunbeam Talbot Ten with cut out for the chain. As always, contact Justin if you're interested sales@mindparadox.co.uk

Sunbeam Talbot Ten - Electric Fan and Mechanical Thermostat

 With the loss of the inbuilt fan on the Dynamo we decided on a 12v electric fan fixed to the reverse of the radiator. The fan is fixed with 4 plastic ties that pass though the core of the radiator.

To control the fan we used an adjustable Mechanical Thermostat, to ensure we don't overcool the engine we can adjust when the fan turns on. 

The Thermostat uses a Common, Normally Open (NO) and Normally Closed (NC) contact. Once the required temperature is reached the NO contact closes and the NC opens. The stat can switch 10Amps and can therefore control the fan directly however I've installed an additional relay in the new fuse box to allow for a different control in the future.

As is becoming the norm, the 3d printer came into its own and Justin designed a simple enclosure. If you wish to purchase contact sales@mindparadox.co.uk

It is fixed in the front of the engine bay and the sensor is tucked into the top radiator hose under the jubilee clip. 

 

Radiator Fan

The fan is wired in 2mm thin wall cable via 2 pin AMP connector.