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.

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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.