Onboard welder using a GM Delco 140 Amp alternator
out of a '94 Chevy Camaro
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Modifying the alternator...
Here are some pictures that show the inside of the alternator with the components labeled:
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| The alternator case | Connections on the back |
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| The connector that needs to go | The inside |
You basically need to remove the regulator (I just disconnected it) and the exciter diode. Then hook the 12 volt field power directly to the field brush (upper or inner brush). The other brush should be ground to the case by design. These picture shows how I made the connections using a 10 gauge wire soldered directly to the brush terminal:
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| Field wire | connected to field brush |
I opted to mount the external rectifier that I was given somehow and take the power off of it directly. This required that I remove the factory rectifiers (shown below in picture) along with their heat sinks leaving the plastic support mount with the studs that the stator wires mount to in place.
I hooked up three 10 gauge wires to the stator leads leading the 3 phase outside the case to the external rectifier. This is what the external rectifier looks like with the 3 phase wires going to it mounted on the alternator support bracket:
