International Lancia Forums

As per advice recieved here I took my generator (mileage unkown) off for a rebuild. The specialist took one look and said "I see your problem". It seems the pulley is worn to the point that there is no more V and the belts are slipping, indeed the inside of the pulley is highly polished (by the belt). I also questioned why I was out of adjustment range. Now I have a rebuilt generator and new voltage regulator ( both test good) but I still have the problem of the pulley.
Is a new pulley available?
The other option might be to have the pulley "welded up" and remachined. It seems the pulley is aluminum with a steel insert so it would take a welding specialist.
Has anyone run across this problem??
I miss driving my Fulvia

Would a slightly shorter belt help?

Peter

As Peter says a shorter belt may help. I use Gates belts with a length of 732mm. Both belts are the same. I forgot the number on the way home.
I am not sure what the proper english term is but let's call it the castellated belt is already a lot better on worn pulleys than the old fashioned straight belt.

Of course a new pulley would be best. The do (or at least did) ocassionally appear on eBay.

I dont think a new (shorter belt ) would help much as there is really no V for the belt to have friction. I think Huib's idea of castellated belt might work short term. I am trying to source a new or better pulley, if that fails I will have one made.
Is this common with Fulvia generators?

The pulley is aluminium. At least most are. They wear faster than steel pulleys. I used the last aluminium one I had in stock on a customer's car two weeks ago to replace a really bad one.

I still have a unused steel one in stock. It is not going anywhere as it has to serve as an example for duplication if ever necessary.

Unfortunately stacking standard pulleys with spacers does not work as the spindle of the generator is too short.

Did you try the sponsors above? Casa Fulvia is my workshop. I don't have any left to sell. If everyhthing else fails I can ask my machine shop to do a batch.

My pulley is aluminium with a steel insert where it mounts on the shaft. It's original as it still has a small Lancia stamping on the back.The steel one must be quite heavy as it is a large assembly, that would put even more strain on the front of the generator.
I have a machinist that also repairs aluminium road wheels, he says he can build up the pulley with welding and then machine the V to match the belt. Labor rates in my area are still reasonable.

Sounds like a good idea.