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What is your failure mode? If it is the diode
pack then it is most likely that you need the cooling air to impinge directly on
the diodes. I have a 175 hours on an automotive alternator (70 amp) and no
problems so far. I am sorry but the model escapes me. But it was a
rebuilt model by a local rebuilder. Cost me a $100.
You might also be trying to draw too much from the
the alternator. 35 amps is quite small and depending on your load you may
be operating it at the top end of its output.
If you are frying the windings as a failure mode
then you have a an overload problem.
You can adapt almost any small automotive
alternator to fit. I have an IO360 A3B6D and I had to change the
bracketry. I also changed the alternator pulley size. There is a large
increase in speed when you compare the ratio of the driving pulley to the
driven. If your rotor windings are failing due to becoming loose then you
may have an overspeed condition. Car engines can potentially rev faster
but nowhere do you see the difference in pulley sizes you see on an
aircraft.
Hope this helps
Ian Crowe
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