One of the challenges I'm facing in dressing up my under-hood area is the alternator. I can't swing chrome etc. I would like to know what can be done to get a good finish on the alternator housing. Wire brushing comes to mind, but would entail measures to assure that the resulting dust could not get into the slots in the housing and create havoc with the windings. Any suggestions?

 

Check out what these guys have they have an alternator cover and I believe it looks real nice
http://www.americancarcraft.com/

 

If you are going to wire brush your alt make sure that you seal it up pretty good as particles entering it can really hose it up.
Happy MODS to you.

 

The alternator can be taken apart, sanded and polished. The more time invested the better the finish will be. The pulley needs to be removed first, some grinding on a large box wrench will allow it to grip the pulley nut while a Torks bit holds the center shaft. The black regulator cover needs to be removed. Some RTV needs to be pulled off the regulator assembly so the two brush screws can be seen and removed. A large soldering gun is needed to unsolder the three stator wires from the regulator assembly, solder wick helps remove the solder. The regulator assembly can be unscrewed and the case halves separated; set the stator and rotor aside. The pressed in studs can be tapped out and tapped back in for reassembly, note the length and location first. Remove the bearing retainer and bearing from the case. The case halves can be filed to remove the sharp casting flash then sanded. Tight areas can be blended using a small file with sandpaper on it so no deep scratches or gouges will be visible when finished. A small piece of 1/8" - 1/4" thick rubber works well as a sanding pad. Use desending grits of sandpaper until 1500-2000, this will provide a good base to polish. A drill press and buffing wheel work well, cheap wheels and polish can be found at Harbor Freight. The area of the stator between the case halves that will be visible can be cleaned, masked off and painted. Check the bearings and brushes and replace if they are worn out. Use some new white silicone heat sink grease between the case and regulator assembly, Radio Shack should have this. If you take your time the completed alternator will have a mirror finish.

 

I polished my TB, thermost housing, tensioner, ataltenator and the large bracket it attaches to. Used 3M surface conditioning discs, hand sanded a little then took the grinder using a round buffing wheel and brown tripoli and green rouge to shine it up...same process as wheel polishing. Came out great
Here's a page that may help http://www.nomma.org/support/finishi...Polishing.html

 

Here's another good source on metal polishing : http://groups.msn.com/Camaro2001SS/polishinghowto.msnw

 

Fast one; very informative.

 

These guys are almost walking distance from me, and I didn't know they were there!!
If it was a snake it would have bit me.......