Previously I have fabricated the alternator mount and tensioner assembly (http://mearcatmini.blogspot.com/2011/07/alternator-mount.html) but due to it's position, the alternator has to partially sit in the drivers wheel well which means having to cut some of the inner guard away. The hole must be a neat one and like everything else I've done so far, I've tried to make it look like it was supposed to be there, not an after-thought.
The first step was to cut a large part of the inner guard away. This was of course done in the white Mini front cut.
The alternator etc was bolted in and I began making some cardboard templates for the sheet metal that will surround the alternator. There is a big gap on one side of the alternator for a reason - once the alternator is unbolted from it's mounts, it has to be moved towards to the rear approx 30mm to clear the mount and pull it out. I intend on making a cover piece for this section (painted same colour as the rest of the Mini) that will hide the large gap once the alternator is in place.
The template was then transferred to the good shell and taped in place.
Hole cut out and new piece of panel welded in. This hole was enlarged later one once the engine wsa installed and I needed room for the alternator tension adjustment.
The first step was to cut a large part of the inner guard away. This was of course done in the white Mini front cut.
The alternator etc was bolted in and I began making some cardboard templates for the sheet metal that will surround the alternator. There is a big gap on one side of the alternator for a reason - once the alternator is unbolted from it's mounts, it has to be moved towards to the rear approx 30mm to clear the mount and pull it out. I intend on making a cover piece for this section (painted same colour as the rest of the Mini) that will hide the large gap once the alternator is in place.
The template was then transferred to the good shell and taped in place.
Hole cut out and new piece of panel welded in. This hole was enlarged later one once the engine wsa installed and I needed room for the alternator tension adjustment.
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