Niva alternator lift

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Hi, comrades. This video will be useful for owners of carburetor Niva. So, let's begin. The idea of transfer of the alternator to higher ground occurred at the moment of buying new, which was 80 Amps. The new alternator at its design was completely open and exposed than the old ones. Even when you overcome the minor obstacles of water, alternator was all in water. Surfing the Internet allows you to find the finished version of this device in the stores. But I decide to create a bracket by myself.
This view of factory bracket.
All size is specified in millimeters.
The bracket consists of two parts. They will be joined by welding.
The drawing was printed and transferred onto the cardboard, for further convenience.
Now we have a paper model of the bracket.
Put your model into the place. You need to be sure the full coincidence of all sizes.
It’s great. All sizes of the model were correctly printing, now we can put it all on the metal.
After reading the reviews on the choice of metal thickness, it was decided not to skimp and make a bracket out of 5 mm sheet. Why this thickness? 3 mm over time, is bent, its thickness is simply not enough to support the alternator, because the bracket holds it, and provides the belt tension. The best was 4-5 mm sheet. I have got a 5, so put a model, draw on and sawing.
Well, that something starts to turn and become like future detail.
Unpolished, rough piece of metal has burrs, which are advised to treat immediately, because they are very easy to cut hands.
Left margin on the weld because I do not know which side will be welded in the future. To It’s not so long to whittle away the excess.
Next drill holes for the bolts.
Metal is thick, the drill is constantly off, drilled as long as possible.
Well, where do without elaboration file?! Hold the detail in the Vice and make a hole to the desired diameter.
Painstaking work, but the hardest part lies ahead.
Slowly, gradually come to completion.
In the example, the workpiece is ready, bolt on 10mm installs easily, now pushes the workpiece to the side and move on to making the second part.
Something like this.
So, let’s go to the next stage of manufacture of the bracket. This is perhaps the most difficult part.
Drawing and sawing again. First of all, sawing a smooth space. All curves is for the jigsaw.
Here he is , waiting in the wings!
Specifically for these purposes was purchased saws for metal, with a cutting thickness of 1-3mm. Unfortunately, but others have not found.
And what do you think?! The blade turned blue, overheated, dull and unusable! Not flooded as they say! Take an angle grinder and cut in all directions!
Sawing carefully so as not to damage the item.
After some manipulations, we have the following! Because our jig saw can't handle, then have no choice but to make cuts and finish with a file!
Cuts can be done often, so then the item was easier further processing. I left as is, and went forward to the vise.
Here is the result, after a hard friction with a file.
Try to do carefully, do not forget to grind off sharp areas.
From time to time check with the cardboard model, in order not to go astray.
Rounds all sharp corners.
Small defect, but the operation of the bracket will not be affected I think.
Inspect the item and remove all sharp edges with a file again.
It remains to complete the time consuming part.
Well actually something like this! The process is not so hard as it seems, but I think patience should be reserved.
Looks not bad, but it seems that during the fitting will still have something and somewhere to customize.
Parts met each other.
I like it. Painting did not, the details should be customized and weld.
It was spent 2 hours of time.