Powergen

[tbirdtommy]

Has anyone installed the Powergen alternator conversion on their Bird? It's the one that looks like the generator but is actually an alternator. I am having troubles trying to figure out the wiring. Thanks for any help.

[OldRusty1]

I have installed this system on my '62 non A/C Convertible. PowerGen P/N 82158-2 and Charge Wire P/N 1-36-130. I ordered direct from PowerGen as the standard supplied pulley (shown below) is incorrect for this application. They had to supply a pulley with the groove spaced out by one belt width to match the original spacing. Non A/C cars use a single outer groove.

Wiring from the PowerMaster Gen:
Attach the Red Charge wire from the back of PowerGen (output) to the hot side of the starter relay.
Fabricate a short ground wire from the PowerGen ground terminal post to the engine block at the battery ground cable connection.
Attach the Yellow w/Black stripe wire to the Light Terminal post on the PowerGen.
Insulate and deadend any old remaining wires in the harness at the generator end that remain from the original generator installation.

Your Voltage Regulator will remain as a terminal board. Just remove the springs and associated contacts.

Works for me like a charm for the last three years.

[tbirdtommy]

Thanks for the help. I'll get on this sometime this week and let you know if I have any other questions.

[OldRusty1]

Almost forgot, I also had to install a shorter fan belt. Installed a NAPA Premium XL 25-7435.

[ToniR]

@OldRusty1:
Did you order a special made pulley or is it the standard step pulley (number 1139) from the Powermaster catalog?
I am planning to get one for my non AC TBird.

[OldRusty1]

PowerMaster, at the time, did not have a step pulley for this application. I was the first installation requiring this and they custom made a pulley for me. It appears that they have now made this part a stock item. You should be able to order the PowerGen with the step pulley installed directly from PowerMaster.

Regards,
Old Rusty1

[ToniR]

Thank you for your reply!
I noticed that it says now in the description that the alternator is with the step pulley.
That is why I was a bit uncertain...

[ToniR]

Powermaster alternator is already purchased, but the conversion is still on hold.
Before I start, few questions came up to OldRusty1:

- I noticed that you left the regulator "A" coil in place. Is it OK that way or can I take that coil out too?
- Did you use existing generator wire to connect the light terminal post and did you connect that via old regulator?

Otherwise I think I am good to go.

Thank you in advance.
Toni

[OldRusty1]

ToniR,
Connection at the PowerGen: Use the existing Yellow with Black Stripe generator wire and connect it to the Light Terminal Post on the PowerGen.
On the Regulator, it's OK to leave the "A" coil in place as I did.
No changes or adds to the wiring at the Voltage Regulator, just leave it as is.

PowerGen Wiring

Voltage Regulator

6+ years of trouble free operation -
Plenty of power to operate the top and no more headlight flicker at night when stopped and in gear.
You should be fine with your installation.

Regards,
OldRusty1

[ToniR]

Thank you for your additional comments!
I am a bit cautious about all electrical work, especially with old cars.
Now everything is clear, thanks!

[Mvs62bulletbird]

Old rusty and friends. Maybe I’m a bit confused on the topic but on the 62 Ford Thunderbird Rusty, it looks like it was just a plug in that you plugged in in and tightened in place connected to the wires and you were good to go.

Is that All I’m looking to do on the Thunderbird from what I can see it looks like it’s a 12 V generator that stepped down to 6 V for the dash lighting, etc. and as long as they put in the new 12 V alternator that looks like the 12v generator from power master it should just be take the old generator out snap the new alternator in the long one that fits on the existing mounting brackets and we’re good to go is that it is there any other surprise I need to be aware of or think about
Thank you for your quick response. It’s very appreciated Michael.!