charging issues
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Cold (1200 rpm at insanely low temps, 1000 up to 89 degrees, F, both in neutral).
Warm 650 rpm in neutral, 550 in gear (approx. 200 F).
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First, you now have 2 crank pulleys and 2 alternator pulleys, right?
Second, the important factor here is not the absolute diameter of each pulley, but the relative size in relation to each other. Let me give some examples:
a) C1 pulley is 6 in diameter, A1 pulley is 2 in diameter. This is a ratio of 3:1.
b) C2 pulley is 4 in diameter, A2 pulley is 1 in diameter. This is a ratio of 4:1.
c) C2 pulley matched with A1 pulley is a ratio of 2:1.
d) C1 pulley matched with A2 pulley is a ratio of 6:1.
Hopefully, you can see where I am going. You should be able to mix and match and get a better ratio to spin your alternator faster. For example, measure the 2 crank pulleys you have. Select the larger of the 2. This will yield the highest inches of belt travel per engine revolution. Measure the 2 alternator pulleys and select the smaller one (sounds like the original one will do). This will give you the highest ratio of alternator rotation per crankshaft rotation (like example d). Using that combination, you will have the fastest turning alternator at that point. Cost, possible one drive belt (if it works out).
Hope this makes sense.


