Re: 55 years ago I was given this USAF 54 3100
 

I refused to really learn how to type in HS now i type all day!!!

Learning
 

Learning is good, I crave knowledge .

A good mechanical connection is critical to a proper soldered joint .

I find it very sad that NAPA isn't the top quality partshaus they once were .

Re: 55 years ago I was given this USAF 54 3100
 

Well progress (?) is made. Old alt is out and new one is in. The lower alt bolt is too long to remove without removing the whole bracket that mounts to the water pump. Seems i forgot the radiator is so close to the engine. Installation of the new required preassembly of the alt and bracket with lower screw installed but loose. Luckily the alt can be rotated out of the way to reinstall the bracket screws and ground clamp to the water pump. That's all this 75 year old can stand to do for today. Tomorrow will be wiring to the battery and the main fuse.

Progress !
 

And there you go .

Baby steps will get you where you want to go .

Re: Progress !
 

FIFY!

"Geezer steps MAY get you where you want to go"

Took a day off due to our one day of 82F here at the beach. Back to 60F today and all the fishing boats are still running around under our window after the Coho salmon run in the Siskiyou. Trying to finish new wiring today

Re: 55 years ago I was given this USAF 54 3100
 

I'm not clear what "FIFY" means but you're right about geezer steps .

Re: 55 years ago I was given this USAF 54 3100
 

FIFY = FIXED IT FOR YOU New jargon every day. Geezer steps for sure especially with plantar fasciitis. Ran the 4 gauge to the alt and battery. Had to sleeve the 4 gauge as the fancy gold plated multi terminal is set up for like 2 gauge with a single set screw that would just push the strands out of the way when tightened. Tried solder but cable wires seem to be all coated and no stick even with flux and acid or rosin. Will post pics next time if anyone cares about a simple project turned not so simple.

Re: 55 years ago I was given this USAF 54 3100
 

Well thought i should finish wiring and take some pics while i'm still in the upright and locked position. Runs great with 14.5 volts at idle and 13.8 with big amperage SPAL fan running flat out. Used to drop to near 12 or less at time with the old alt as said before. This may be the last alternator for this old man and no mas! Heres some pics. first two are with the old set up with the 63 amp one last 3 are the new one 94 amp and a pic of the fancy gold plated battery connection that provide much grief. Will spend the am reinstalling the wire looms and cleaning up the works. Now onto to low speed cruising!!

Re: 55 years ago I was given this USAF 54 3100
 

Well done. I have a suggestion/question though. Do you think it might be a good idea to move that fuel filter away from the wiring? It appears that fuel line may be leaking slightly. It looks like there's crude on it.

Re: 55 years ago I was given this USAF 54 3100
 

Thanks will check it today before the test drive. Might be from previous leak. This is a "fair weather" daily driver right on the ocean so gets dirty fast. Speaking of "fair weather" the monsoon season starts tonight!!!!!

Re: 55 years ago I was given this USAF 54 3100
 

If having trouble with the rubber to steel line try a fuel injection style hose clamp. The gear clamp style tends to cut into the rubber hose and can deteriorate the cotton reinforcement threads. Fuel injection style hose can also help because it is rated for more pressure so has better reinforcement properties.

Alternator Upgrade
 

Looking good .

Fancy-schmancy cable clamp there .

Re: Alternator Upgrade
 

Chinese gold plated lead. Had to enlarge area between terminal clamp "legs" to get tight fit. Also Takes both US and metric hex wrench's to install but does the job. Nice to see voltage stay above 13.8V regardless of load. Will say SPAL did have a warning about amp draw. They weren't kidding.

Re: 55 years ago I was given this USAF 54 3100
 

I wonder why ? .

I've used many electric fans and never had one draw more than 6 amperes unless it was worn out and beginning to drag .

Chinesium : great when it works, less so when it doesn't and often only a 50/50 chance either way .

Re: 55 years ago I was given this USAF 54 3100
 

Spal specs and users say 28A with peak at 50A. They recommend a 70A relay. Moves/pulls like 2800 cfm and swear truck accelerates when it goes on. Does cool engine fast but loud. Like everything in life, truck is ready to roll BUT monsoon season was in full blast as of yesterday and raining like h-ll!!

Re: 55 years ago I was given this USAF 54 3100
 

post 382, when you say the solder wouldn't stick. is your cable copper wire? I have heard of aluminum core cable. most copper cored cable with a coating on the copper has a tin based coating and solder would easily stick to that. there is aluminum core cable out there though.

Re: 55 years ago I was given this USAF 54 3100
 

Cable is high quality copper made for marine use and was all I had on hand. I suspect that the copper strands are individually coated with anti-corrosion stuff that is very hard to remove and worse when heated. I do a fair about of soldering in building ML rifles so familiar with many types of materials and fluxes. Luckily was using a sleeve and crimp connection to that fancy terminal shown. I share your concerns about all the chinese AL core stuff out there. Remember the ban on AL house wire???

Crappy Wiring
 

I certainly remember the house fires ! .

I was a wee lad then and I knew it was a bad idea .

Re: 55 years ago I was given this USAF 54 3100
 

as a pro structural firefighter I have been to a few of those house fires from electrical issues. lately there have been a few caused from trades guys who use cordless drills to tighten gown the screws in the electrical panel. some get overtorqued and after awhile there is a loose connection from a stripped screw. that took awhile to figure out. a bunch of houses in the same area prolly had the same tech pr apprentice doing the work.

Poor Workmanship
 

This is *exactly* why I never took to using those handy and time saving electric screwdrivers ~ in my long career I've been stuck by so many damaged / stripped fasteners because the DPM/DPO used one .

Re: 55 years ago I was given this USAF 54 3100
 

Put just under 100 miles on it. Voltage stays at 14.2 - 14.5 without fan 13.8 with. I checked across battery terminals with a good meter and its the same. No voltage loss now, Did this cause alternator guy said gauges are not 100% accurate. Another pleasant surprise is seems new alt automatically excites - this being as alt light goes out immediately even with low rpm starts -- no revving needed. All lights seem brighter as well. Does sound different with the plastic alternator fan. Alt guy says these run cooler due to enclosed design. May say I wish I had gone with a all new wiring harness instead of taking the pot head mechanics recommendations to retain the original 84 chassis stuff. What a mess!!

Good News
 

Why I hate vipers, drunks and tweakers .

Now, go drive the hell out of it .

Re: 55 years ago I was given this USAF 54 3100
 

Sadly the coastal monsoon season will limit its use. Only the Veterans Day parade is on the schedule.

Re: 55 years ago I was given this USAF 54 3100
 

Just got a bit of a shock. Take a look at my brand new fuel filter. Look close and you'll see the filter cartridge has completely detached from the metal base and is floating about doing absolutley nothing but possibly impeding fuel flow to carb. Second pic is what its suppose to look like filter glued to metal base. Chinese junk!! And worst supplied by Edelbrock with the brand new 1406!!! It happened as well on the previous filter next to the tank!!. Heads up on this crap and better check yours if you have a similar one. Will be replacing both with a good filter as soon as i can find one NOT MADE IN CHINA!!!

Re: 55 years ago I was given this USAF 54 3100
 

what size is the fuel hose?
I personally try not to use the plastic filters under the hood where a leak could spell disaster. I have had good luck with the delco GF61 steel version with hose fittings on each end. I know you can't see the fuel inside like the plastic ones allow, but these can be clamped to a bracket with a hose clamp to keep the strain off the carb fitting and the steel lines coming up from the pump or frame. vibration kills, possibly a reason why the glue gave up in the plastic one (or maybe just a poor quality like you said). i have cut these steel ones apart before to check what the system has in it and found I had to cut the paper element because the resin glue was stuck like concrete.
just a thought. they are also cheap to buy and every decent parts store usually has a bunch.

https://www.oreillyauto.com/detail/c...lter/acd0/gf61

https://www.classicparts.com/1985-91...tinfo/84-2171/