peugeot 403 alternator conversion
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Thread: peugeot 403 alternator conversion

  1. #1
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    Default peugeot 403 alternator conversion

    hi.
    I am thinking of getting alternator to fit 403 engine in my 203 wagon.
    I did some search and could not find much. there are few who did it but no
    detail which alternator from which car will be the best fit with not too much work .
    thanks
    Ron

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  2. #2
    1000+ Posts robmac's Avatar
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    Any alternator conversion on 403 will be quite a lot of work.

    There is simply not room to mount an alternator easily off existing engine lugs. You need to fabricate a bracket

    If you use some 50mm x 50mm x 5mm angle it's possible to weld lugs inside the angle to pick the lugs on the block.

    And then weld lugs on the outside to mount the alternator.

    I suggest you use material of 5mm minimum thickness.

    A 404 top (tensioner) bracket, which has been bent and extended will pick up the existing top bracket bolt.

    If you are good at fabrication it's straightforward.

    If the car has a wide A section, fan belt you will need to find a small diameter wide pulley to suit the alternator shaft. Sometimes you need to reduce the pulley hub width to fit the alternator shaft length.

    A good hardware store should have an alloy pulley, keep the diameter as small as possible to make alternator run as fast as possible. Don't use the grub screw to fix it. Clamp as per the original pulley.

    If the car has a narrow, 3/8 inch width belt (403b?), donor pulleys are easily sourced from 404s, 504s or many other cars.

    I'd suggest a Holden Bosch alternator as per this thread:
    gererator to alternator conversion.......

    Best of luck.
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    Here's an alternative from Europe.
    From a reputable ?Dutch? business that also restores early, expensive pre-war Peugeots.



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    The alternator is mounted off the tensioning lug sub optimal for reliability.

    I have my doubts if it will fit into a 403 - grid lock with the fresh air duct ?

    FWIW the image is of a 203 engine. The 203 body doesn't have fresh air ducts.
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    Hmm.

    It looks like the fan belt tensioner assembly is mounted to the tensioner bolt, surely the main support is through the alternator lug and block lugs, hidden below & behind the alternator.

    An alternator is smaller / about the same size as a genny.
    It should fit where the generator was.

    The intake casting indicates this is intended for use on a 203, although there is a 5 bladed fan.

    I hope to use an alternator, as ~60 year old generators are too unreliable
    Sadly, 2 have failed in my cars in the last few weeks.

    cheers

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    just wondering
    a. what carb. is that and
    b. the engine mount - is that a test bench adaptor, or what application ?
    grandC4picasso RHB, [email protected] , EGS6Sp, B58, MY 2012-2013 (?)

  7. #7
    1000+ Posts robmac's Avatar
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    Quote Originally Posted by DaveB View Post
    Hmm.

    It looks like the fan belt tensioner assembly is mounted to the tensioner bolt, surely the main support is through the alternator lug and block lugs, hidden below & behind the alternator.

    An alternator is smaller / about the same size as a genny.
    It should fit where the generator was.

    The intake casting indicates this is intended for use on a 203, although there is a 5 bladed fan.

    I hope to use an alternator, as ~60 year old generators are too unreliable
    Sadly, 2 have failed in my cars in the last few weeks.

    cheers
    I've tried mounting off the tensioning lug and long term the lug fractures.

    It's not that hard to come up a sturdy bracket using the mounting system the manufacturer intended.

    Easily available alternators are always much larger in diameter than the original dynamo.

    You also have to consider belt wrap on the drive pulley. Granted, less may be acceptable on wide belt . However you should still aim for around 50 % or more wrap, if possible.
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    Agree, would be crazy to expect the tensioning lug to support the weight under load / vibration.

    My spare Alfa alternators are about the same diameter as the 403 generator.
    My 203 doesn't need more than an 85 Amps alternator provides. (YMMV)
    It's Bosch as per BMW / Audi / FIAT etc.
    IIRC, modern ones are smaller again, but require multi-tooth belts to drive.

    The carb looks like a 50's zenith.
    At least the block is 403, it has an alternator attached by a respected restoration outfit.

    Didnt mean to start anything, just saw a relevant photo that might interest patrons.

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    An expensive ( 400.00 - 800.00 ) alternative is to get the generator converted to an alternator, which would look externally original and save you messing around with mounts

    The sensible solution is to find somewhere to put an alternator and fabricate the mounts, but I am not a sensible person, so am investigating the above option for the 4CV. This is the practical solution if not fussed about originality of appearance and the time taken in fabrication/experimentation.

    There is a sparky in Castlemaine who does it, also a crowd in Sydney

    Alter-Gen
    Phil: 02 98321630

    Best Wishes

    Andrew





    Quote Originally Posted by pug407 View Post
    hi.
    I am thinking of getting alternator to fit 403 engine in my 203 wagon.
    I did some search and could not find much. there are few who did it but no
    detail which alternator from which car will be the best fit with not too much work .
    thanks
    Ron

  10. #10
    1000+ Posts robmac's Avatar
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    There is a sparky in Castlemaine who does it, also a crowd in Sydney

    Alter-Gen
    Phil: 02 98321630
    peugeot 403 alternator conversion-ag-01.jpeg


    At $800 and much larger in diameter than the original dynamo.

    I can't see the benefit and spare parts are likely propriety.

    Compared to $40 for used Bosch alternator and a couple of hour fabrication, I know the the choice I'd make.

    EDIT: The smallest alternator I've sourced is a Mitsubishi LR , fitted to Subaru Leone and Brumby rated at 35(?) amps.

    They are 130mm diameter, compared to Ducellier dynamo which are 110 mm in diameter.

    But be prepared to pay $$$ for electrical spares.
    Last edited by robmac; 20th August 2017 at 05:53 PM.
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    Spoken like a sensible person

    Still dithering about this for my 4CV project, also about 6V alternator, which can be made to blend in and is a bloody sight cheaper

    Andrew

    [QUOTE

    =robmac;1532733]Click image for larger version. 

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    At $800 and much larger in diameter than the original dynamo.

    I can't see the benefit and spare parts are likely propriety.

    Compared to $40 for used Bosch alternator and a couple of hour fabrication, I know the the choice I'd make.[/QUOTE]

  12. #12
    1000+ Posts robmac's Avatar
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    I's convert vehicle to 12 volt and do yourself a favor. Then everything becomes "auto standard" and the load current is halved.

    And a 12 volt battery don't look too different to 6 volt battery .

    A 6 volt three terminal regulator for the dash instruments costs practically nothing.

    4Pcs L7806CV ST 6V 1.5A Voltage Regulator TO220 LM HA17806 PIC AVR Arduino | eBay

    make sure you fit a heatsink sink 'tho.
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    Default 12v v 6V

    Dear Rob

    Thanks for this, which had been one of the array of potential solutions.

    Mercifully there is not much in the way of electronics on a 4CV ( fuel gauge and sender, wipers, horn, starter, lights , coil), some of which would be happy enough at 12V, others less so

    Sorting out the cross-talk between the various bits and voltages will make my brain hurt, but it will be a learning experience

    Other part of it will be lotsa relays and earthing blocks so as not to be hostage to old switches etc

    Best Wishes

    Andrew



    Quote Originally Posted by robmac View Post
    I's convert vehicle to 12 volt and do yourself a favor. Then everything becomes "auto standard" and the load current is halved.

    And a 12 volt battery don't look too different to 6 volt battery .

    A 6 volt three terminal regulator for the dash instruments costs practically nothing.

    4Pcs L7806CV ST 6V 1.5A Voltage Regulator TO220 LM HA17806 PIC AVR Arduino | eBay

    make sure you fit a heatsink sink 'tho.

  14. #14
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    Hopefully the starter and wiper motors share the same footprint as 12 volt successor.

    Otherwise a 6v starter powered by 12v , tends to chuck the engine out of the car. albeit for a short space of time.

    I've been through that on my mates 48-215 many many years ago.
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    An alternator from a 1 series Volvo will bolt straight on, mine has lasted in rallies and other harsh uses for 25 years now. Use a bolt and several nuts so that both the bottom lugs take the load. Just need to adapt the tensioning bar a little and of course need to use a narrow crank pulley.

  16. #16
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    Presumably in 203 and not a 403 as in the thread topic.

    The conversion I did many years ago in 403 had grid lock with the fresh air vent ducts. Which is reason I lifted the alternator up higher.
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    No, 403 and 203.

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    Ron....
    I managed to find a new old stock 1978 Honda Civic alternator with external regulator, although only 30A it still works far more better than the dynamo. The best part is it only has two mounting, fits perfectly at the existing dynamo mounts and the alternator pulley aligns well to crank pulley.

    peugeot 403 alternator conversion-20170828_125152.jpgpeugeot 403 alternator conversion-20170828_125059.jpgpeugeot 403 alternator conversion-20170828_124905.jpgpeugeot 403 alternator conversion-20170828_124936.jpg

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