Images of pulleys and belts

When I last replaced the alternator, I converted to the highest amperage three wire Lucas alternator that would fit. It turned out that the diameter of the pulley shaft was smaller than that on the alternators that the kit was designed for. When I went to install the new pulley on the alternator there was no way that it would fit. Even if I wanted to swap alternators back to the original style, it was well after ten PM and none were available. I made a bushing by taking a disposable aluminum pan like those used for Thanksgiving turkeys, cutting a thin strip of aluminum out of the bottom of it and reeling it onto the shaft until it was the proper diameter. No, it's not the right way to do it, but it worked.

Since the waterpump was drilled for several different bolt patterns, it would attach just fine to either the new pulley, or the fan. Again, I was bit by the effect of using junkyard parts for years. The pulley and the fan had different bolt patterns. I drilled a second set of four holes in the pulley, 45 degrees ( pi/4 radians for the mathematicians) off from the orignal.

The instructions mention how important lining the pulleys up is, and even lists tolerances. They are not kidding. I was shredding the outside rib of the belt about every 1000 miles. At $25-30 for the belt, this got a bit expensive, until I reshimmed the idler pulley to bring it into line with the other pulleys.