A few little updates, since it's been a while since I've updated this thread.
I was able to track down a fan shroud for my radiator, which has helped a lot with engine temps, particularly while using A/C on hot days.
Then, my alternator died again
. This is something that's recurred too many times for my liking.
I'd been paying attention to the voltage while running, since it's displayed on my Sniper handheld unit, and had noted for the last few months that sometimes it'd be at 12v, sometimes at 13v, etc and would dip and climb, dip, climb, but never really get to a full 14 - 14.5v charge.
Then, recently, it dropped to around 11v and was no longer charging.
I did some research and found that I have a 1G alternator setup. I think my alternator makes, at most, about 60amps. With fuel injection, a stereo amp, A/C, high energy ignition, etc. etc. I imagine I'm just overtaxing it and burning it up.
I went to the junk yard and pulled a 130 amp 3G setup out of a '95 Ford Windstar minivan, along with the wiring for $30. Drove it over to O'Reilly and had it tested and it charged great.
Pulled my old alternator out (which I'd swapped out under warranty from O'Reilly probably 3 or 4 times by now).
The 3G dropped in very easily with no modification (I'd read in some writeups there was grinding needed to get it to go into the bracket, but I had no such issues).
Pulled out the old wiring along with the voltage regulator.
The heavy gauge wire from the Windstar was really long. The alternator was on the passenger side by the grill, and the wire ran all the way across the engine bay and then back to right in front of the firewall on the driver's side to the battery. So, it was plenty to work with. (The big orange/black wire)
I'd read where you want to put in a 175amp fuse, but this one has a built in fuse into the wire, so for now I'll leave it at that.
Cut the wire and crimped on a nice connector.
Grabbed the plugs that came with it and wired them in.
Went to fire it up and the whole Bronco was dead. Had to do some diagnostics of the original wiring and realized that with the 1G setup, the interior power is meshed in with the alternator wiring. So, I had to run a new power wire to the plug that goes into the cab (the yellow wire).
After that, it fired right up!
Before (voltage in lower right)
However, then came the next obstacle. The belts squealed badly. The single belt I ran on the alternator was simply not enough to turn the 3G.
Normally, I'd have just run 2 belts on the alternator, but the middle groove is what my power steering runs on. I tried a few different combinations of belts, such as running two super-belts around both the alternator and power steering, but this left way too little grip on the balancer and water pump pulley, so this squealed even worse.
So, since I still had to get to work the next day, and had not forseen this issue before starting, I disconnected my power steering and just put two belts on the alternator. I figured I could drive it without power steering for a few days until I figured things out.
I did some research and found that A/C trucks put the power steering on the middle groove, and non-A/C on the front groove, so I went to the junk yard and found a truck with a front groove pulley. $6!
NEXT obstacle! The stock pump (or the C2 pump) uses an 11/16" bore (0.6875") but the Saginaw uses a 19mm bore (0.748"). So, even though the pulley was ideal, it wouldn't fit on my Saginaw pump.
I went through a few different ideas of things to do, and researched other pulleys, but the options are few and far between, and the pulleys that do work are very expensive (as in $70 - $90).
So, I decided to have it machined out. Took it to the machine shop I frequent and had it bored out to the needed 0.748".
The next day, and $25 later, I had a working pulley. Here it is next to the pulley I've been running (you can see the offset difference with how the snout is in relation to the grooves).
Now with the same internal bore:
Pressed it on:
And, although it's hard to see in the pic, now the alternator has 2 belts, the A/C uses the front groove of the water pump pulley and the power steering uses the front groove of the harmonic balancer!
I've already put some hard miles on it, and it works fantastic.