peter
for sure this is the way to go than draw up a nice simple shrout for the duct tube
i would glue 2 or 3 of those to the alternator http://uk.farnell.com/panduit/mbms-s10-my/mount-cable-tie-al-pk1000/dp/2063572 or thomas and betts tc105
with this you can nice mount and fix a 3d printed plastic housing to the alternator with tyraps
or an alternative
http://www.jeccomposites.com/knowledge/international-composites-news/interesting-solution-nascar-race-engine-alternators
http://www.crptechnology.com/motorsport-case-studies/
this would be the glue i would use to glue tc105 to alternator
https://www.vikingtapes.co.uk/collections/2-part-adhesives-2/products/3m-9323-2-b-a-epoxy-adhesive-50ml-uk-mainland-only?variant=47756067475
That alternator cover
is really neat except that the B&C alternator has the airflow in the opposite direction – front to back. I suppose with enough pressure going into that hood one could reverse it…
The high temperature epoxy I used before was Loctite EA9492. That holds really well at +100C.
It’s a good idea to use clips glued to the alternator and use high temperature cable ties.
I contacted that 3D scanning company and will report on what happens.
I got this reply:
Thanks for your enquiry and detail.
Looking at the thread I suggest this solution.
-3D scan the base component (local area only) £150
- CAD Design component to fit/ join adaptor. £125. Potentially a snap fit plastic or composite.
-3D print/ cnc one off the designed part £50-125 (exact prices known when 3D model created)
Dependent on whether any special material properties required ( heat / pressure etc ) determines end material choice. It may be cnc steel say or 3D printed nylon.
hello
pricing sounds about right
cnc steel would be a no go for me
3d printed nylon sounds like a solution like this also printing costs should be very low
on a other project i had a simple “duct housing” 3d printed for about 8 euros
That looks like it is metal.
According to here, metal printing is widespread – at some price.
This thread says you can’t print in aluminium but points to one printing company which claims to do aluminium, titanium, etc.
It will be interesting to compare printing with CNC.
it is nylon and it is a duct housing to a small radiator to attach a “donkey pipe”
we also use this material on cars to make “brake cooling” ducts on uprights etc as the shape is very complex and for 1 or 2 off to make a mould etc would be massive expensive
Ok it will not last for 200k km but for sure it lasts for a nonstop 24hrs test on a car (and the brake discs are very hot!!!)
for a little project like what u have in mind the perfect way to go
Just for a laugh I did a google on
denso alternator air duct
and I have a feeling that others have been up this path before 
But only for the larger Denso models, not the small one which B&C use.
Maybe I can sell the product afterwards The BC410-1 alternator sells for $2200 so I reckon one could sell the cooling adaptor for, what do ya reckon, $2000? Dammit, I can’t issue an 8130-3, so that puts a stop on that option!
I am amazed that these firms claim that sintered aluminium is as strong as machined from solid.
we have used ti sintered roll over structure on f1 cars
shapes you could not do with a cnc and also due to the non solid way of doing it it is very light and strong
http://www.crpmeccanica.com/ebm-electron-beam-melting/
https://www.3trpd.co.uk/portfolio/titanium-f1-roll-hoop-proves-concept/gallery/automotive-case-studies/
this might be interesting for you could not be done from solid!!!!!
That electron beam melting process looks amazing.
This alternator air duct cannot be CNC machined in one go; I think that is obvious. It could be machined but would need two passes, and a fixture to hold it after the first pass. So it will have to be printed. In volume, it could be injection moulded or diecast with a simple open-close tool (no side actions).
