Build Your Own Air Elimination Bracket for C4 Corvette
Guys, I have seen a number of posts since joining this forum about 6 months ago, and after some research, have decided to add this post to help those of you out there.
First of all there are companies that will sell you a ready-made product that will do this. I cannot comment on these brackets as I have not used one but a quick look at them indicates that they will work.
From my accounts after building my own, the price is about the same, maybe a little cheaper to build it yourself, but there is your time which I do not take into account. Also I have had to base my costs on NZ Dollars, allowing an exchange rate and international shipping. From my calculations the brought item is US$150.00 plus US$20.00 for shipping, total US$170.00, about NZ$212.00, I was able to source everything for NZ$150.00 (US$121.00). The amount of plate and round bar I brought was enough to make 2, so will be even better, only extra would be a second pulley.
If anyone complains about stealing someone’s design, it is easy enough to take measurements, like I did, to measure from the mounting points to the outside of the Air Pulley. I am guessing this is all that was done in the first place. In my case to confirm my position due to the size of the alternator not allowing me to fit Dan's bracket, I measured from the centre of the steering pump to the top far outside of the Air Pulley, then the alternator top mounting bolt to the outside of the far side of the Air Pulley again, placed my template and moved the Dayco pulley till I positioned it to the same distance, marked the centre and presto. Credit is also mentioned within to those persons that provided sources of information.
Now the project. First I need to thank Dan, “Agent 86” for his help in providing the information to start the bracket. However I would advise that if you have an 84 or 85 that you make a template from thin plywood (or the likes) before you make the solid bracket, it appears that the alternator is slightly larger in diameter then the 86 onwards, or I have a larger one fitted for some reason. Dan’s bracket size would not fit on mine.
You can find Dan’s photos with information at http://members.shaw.ca/dankai/Air%20...Delete%20Info/, or do a search for Agent 86, the information is within one of his threads.
If you don’t want to make a solid bracket like this you can make it with flat bar. Word of warning, there are forces in play here so it will need to be made fairly rigid and machine grade aluminium, 10mm thick.
The tensioner pulley in this case is a 109mm ribbed, Dayco #89014. I found that it is best to shop around as prices were varied. In the end I brought mine from “Rockauto”, they were only $13 + $17 shipping, all the others were around $30 + shipping. And yes they were the same Dayco pulley.
Whatever way you make your bracket, the main setup is to ensure the outside of the pulley will be roughly the same position as the original Air Pump pulley.
Looking at the top, from the mounting bolt of the alternator to the pulley centre is ~181mm, from the top left mounting bolt on the cylinder head to pulley centre is ~111mm. If you make the bracket with flat bar (instead of the solid bracket) you should be able to make the upright bar in a straight line with the 2x support mounting holes and the pulley hole.
Ensure that you adjust your measurements so that the pulley insdie bearing seat is no greater then 112mm from the cylinder head, this will track the belt central. 1-2mm either side will get you by but I would not recommend any thing greater.
I have included photos of my install from Dan’s design with my measurements. I plan to take it off one day soon and have the Corvette emblem etched into it on both sides.


Front view of bracket, see the 3 mounting bolts; these fix to the cylinder head with 1x long and 2x short spaces in the back.

Another view of the front.

Shows the alternator mounting point. Bracket is curved to look presentable, think it did the trick.

The 3 mounting spacers, note the long and short spacers. The short ones (2x) are to allow the alternator mounting bracket to be used. My install has this painted met blue.

I hope this helps those looking to build their own?

 

What did you use to cut your aluminum plate?

 

Hi, I used a Jigsaw with a metal cutter blade in it.
Due to using machine grade aluminium it is very hard and will take time to cut.
Do not rush it as you will break the blade.
I think I went through a few blades before I found the correct blade to cut the material.
Good luck in your build and drop a few photos of it afterwards.

Kevin.

 

I always appreciate the owner "made" equipment over the owner "bought" stuff ProjectC4, I like that design! Nice, simple and low profile. How thick is that aluminum bar you used?

 

And like Dan, there is many ways to build your own.
As long as it's designed to take the load, you don't want it breaking and flying off while your driving down the road.
I have looked at building a bracket to remove the Air-Con, as it does not work in mine and taking up space. We will see.

Would you put your measurements and materials in the post, so others can look at it, if they wish to make your setup. https://www.corvetteforum.com/forums...s/thumbsup.gif