Ranger Biodiesel Swap - Alternator Adapters

 To simplify wiring, I decided to mount the original Ford alternator on the VW engine. There's no tensioner pulley for the serpentine v-belt, so I fabricated a hinged adapter and tensioning rod.

The first version of the hinged adapter was made from billet aluminum. 

Next, I turned an aluminum v-belt pulley on my lathe, to match to profile of the original VW pulleys.

Finally, I bent a steel bracket that curves around the outside of the alternator and bolts to the engine block. With an 8mm socket cap bolt and fender washers, I made a tensioner that pulls the belt tight, rather than pushes.

After installing the engine, I discovered that the alternator was hitting the steering u-joint and needed to be rotated higher. The aluminum hinge was at its limit of travel, so I made a replacement out of steel that allowed better clearance.

Ranger Biodiesel Swap - Throttle Cable Adapter

Now that the engine is solidly located and installed, it's time to work through the smaller details. For the sake of simplicity and spare parts, I wanted to adapt the original throttle cable to the VW injection pump. 

The VW cable sleeve was round and the Ford sleeve is rectangular, so I carefully filed the retainer bracket until the Ford cable fit. The next step was the adapter between the cable end and the lever on the fuel injection pump.

My first attempt was a simple block, but I realized that the cable end would slightly rotate in the retaining hole, causing friction and wear.

I designed a second adapter, with a guide slot hand-filed with a partial radius. This radius will support the braided cable itself as the lever moves through its circular motion, without causing the cable end to move. This results in a smooth and repeatable throttle action.