Re: 6v to 12v

[Steven Ayres <comwest@well.com>]

TimD=> A few months ago I wrote an extensive list of things to do when 
=> changing from 6 volts to 12 volts. ... Did anybody save that list, 
=> and the supplement?  

Yup, and a good list it was --

Date: Wed, 05 Mar 1997 22:10:57 -0800
From: "T. A. Dapper" <tdapper@value.net>
Subject: Re: 12 volt

> 
> Thanks everybody for the info you gave me on 12 volt systems.  What I'd
> like to know now is if there is any information available or published
> that describes the process of switching over to a 12 volt system.
> 
> Thanx again,
> Sean Scattergood

Change the cast aluminum fan housing, and install the larger 12v 
generator.  It is possible to get a 12v generator the same size as a 6v, 
so that you do not have to change the fan housing.  Try Bill & Steve.

Change the coil.

Change the chokes.

Change the idle cut-off solenoids.

Change the flywheel.  Use an automatic transmission starter so that you 
do not have to change the starter shaft bushing.  Or don't change the 
flywheel and run your 6v starter until it burns up.

Change the voltage regulator.

Change the battery.  Your battery cover will not fit anymore.

Change the windshield wiper motor.  Or install a resistor to cut the 
voltage.  Or run your wipers really fast until you burn them up.

Change the fuel gage in the dash.  No need to change the sender in the 
tank.

Change the clock.  Or don't worry about it because it won't run for ever 
anyway.

Do something with the radio.

Change the headlight relay.

Change the turn signal relay.

If you have a horn relay, change that.  Change the horns.

Change every light bulb, everywhere.

That ought to about do it.

Tim Dapper

>From tdapper@value.net Sat Mar  8 07:11:13 1997
Subject: 12 v conversion

Yes, my 12v conversion list was incomplete due to the flywheel hub 
design change.  It is probably easier to have a step machined into the 
flywheel hub than to disassemble the engine to have the crank shaft end 
dressed.  Finding the correct flywheel is best.  Finding the old style 
hub flywheel with a removable ring gear (and the correct ring gear to go 
on it) is next best, but harder.  A 6v bendix gear in a 12v starter is 
rare, but I suppose that you could disassemble a 6v starter, and have 
the gear welded and redrilled for mounting in a 12v starter.  Does 
anybody get the idea that a 6v to 12v conversion is quite a bit of work, 
not all of it simple?  

The easiest thing to do if your 6v electrical system is getting tired, 
is to put a 6v horn relay (from a Karmann Ghia) in the solenoid circut, 
so that your soleniod can get a full 6 volts.  You can do a similar 
trick in the coil circut.  If you think your wiring is getting tired, 
try measuring the voltage at the coil.  When internal resistance drops 
the voltage to less than about 5.5 volts, you will have trouble starting 
the car from weak spark.  A similar test at the solenoid will tell you 
that you will have trouble getting the starter to work consistantly.  
You can also replace the stock battery cable, which is about 4 gage (I 
think), with a heavier 0 gage cable to be certain that there is no 
voltage loss going to the starter.  If you change the positive battery 
cable, you might also want to secure the starter ground, by putting a 
longer bolt through the body where the battery is grounded now.  Under 
the car, run a cable from the longer bolt to one of the starter mounting 
bolts.  This gives you a more direct ground, again to avoid voltage drop 
at the starter.  This 6v clean up stuff is a lot easier than a 12v 
conversion, and lets you keep your car stock because no body can see 
your modifications.  Of course, a 12 volt system is not so subject to 
tired harness disease, and lets you use a modern radio.