Date:         Thu, 20 Mar 2003 10:23:59 -0800
Reply-To:     laurasdog@WEIRDSTUFFWEMAKE.COM
Sender:       Vanagon Mailing List <vanagon@gerry.vanagon.com>
From:         Steve Delanty <laurasdog@WEIRDSTUFFWEMAKE.COM>
Subject:      Re: upgrading an alternator? headlights 85'
In-Reply-To:  <20030320173658.32198.qmail@web80205.mail.yahoo.com>
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Tracy wrote:

>I was reading through the new issue of VW Trends and noticed the article
>on upgrading a Bug's alternator for more power. Having a powerful radio
>and other things hooked up all the time, I was wondering if anyone might
>know if there are more powerful alternators available for our Busses. I do
>notice that my dash lights go dimmer sometimes depending on what I turn
>on. For example if I turn on the heater blower while lights are on the
>dash lights will dim a slight bit. Thats just one example.

The Bosch 90 amp alternator woks fine. The problem is the internal voltage
regulator
*really* sucks. It's lazy and causes charging voltage to be quite low. It
also senses
the voltage at the alternator instead of at the battery, so when you turn
on lights and
accessories the voltage drops even lower. It sucks... BTDT.

I fixed mine by hacking out the stock internal regulator and wiring up a
Ford regulator.
I also ran an extra wire from the positive post of the battery to the
regulator so that
the voltage is sensed at the battery instead of at the alternator.

It works GREAT and this change alone will make your headlights quite noticeably
brighter.

This seems to be a common conversion amongst Volvo owners. There are several
sites devoted to installing a Ford regulator on the Bosch alternator.
Here's one:
http://www-unix.oit.umass.edu/~tcroy/fordregulator.htm

A Google search will turn up others. Pmail me if I can help.
It's definitely a worthy upgrade.


>Oh one other thing while I'm posting, I notice that my headlights kinda
>suck. If I bought better or brighter bulbs would that make a difference? I
>dunno if anyone has had any expierence with that? Probably.

"Kinda suck"???  Man, yours must be way better than mine were!
There was no "kinda" about it... TOTALLY suck was more like it!

The stock wiring and headlight switch causes
a very large voltage drop, so the bulbs are starved for power.

There's a very common fix involving a couple of relays and a bit of rewiring
that fixes this problem. Search the archives for info. I understand you can
even buy a "relay kit" from the usual vendors.

I did the relay upgrade on mine, and upgraded the wire size while I was at it
and now I can see!  What an amazing difference it makes, even with the
stock bulbs.

Do NOT put bigger bulbs in until you have done the relay upgrade. The
extra current draw will cook the headlight switch and leave you in the dark.
Besides, higher wattage bulbs draw more current which just increases
the voltage drop across the inadequate switch and wire and the new bulbs
will see even less voltage than the old ones.

Do the headlight relay mods and change to an external Ford regulator
for the charging system and then decide if you still need brighter bulbs.
You'll be amazed at the difference!

Steve