So, I'm trying to finish up a lot of little things I need to do before I move onto new things on the car. The biggest thing that I need to work on is the position of the alternator. On the passenger side of the car, I need about 1/2" to 3/4" more clearance to get my alternator back on the engine. My engine is shifted 1.5" to the passenger side, to allow for space in the pedal area and for the steering system. Because of this, the alternator doesn't fit right.
By looking at this picture, you can see where the alternator bracket overlaps with the frame
And in this picture, you can see, outlined in white, the area that would have to be cut out to allow the alternator to fit.
The bolt that you see in the picture, which the arrow is pointing at, is hitting the frame. It’s preventing the engine from sitting flat on the engine mounts.
I have 3 options:
1) I could mount the motor higher in the frame, so that bolt would clear the frame. The downside is that it would be a lot of work (lot of things would need to be changed), and the hood would be ridiculously tall.
2) I could fabricate a new bracket to hold the alternator. The downside is that I would have belt problems, because I'd have a hard time making it square enough to have the belt run right. I just don't have enough accurate tools (I would be using a square and an angle grinder)
3) I could notch the frame, and add a 1/8" plate to the entire area that is cut out. (So the plate would be about 6" long and 4" high)
I'm leaning towards option 3, but I am concerned about the strength of that spot. I know its a high stress area, since its a spot that connects a lot of steel (5 peices join there). And, the shock mount is inches away from the spot which would be cut out.
What do you guys think?