The cleaner looking bracket is the B&C
bracket. Notice how the bolt is smaller on the
B&C, and the bracket itself is taller.
Otherwise they are fairly similar.
When I ordered, both my IO-540 engine and my IO-390
engine are Boss Mount engines, and the IO-540 is a
narrow deck engine but the IO-390 is a wide deck
engine. Ordering the alternators right from
B&C, they ask if you have a wide deck or narrow
deck engine and then single or double groove
pulley. Well, I had to call them because in
their definition, any narrow deck engine apparently
uses case mount and not boss mount, which is incorrect
in my case. They told me over the phone that if
I have a boss mount, then I want the wide deck
version, either way. Poor use of terminology on
their part because there is too much variety. So
leave the wide and narrow deck out of it. And,
both of my engines being single groove pulleys, I
ordered 2 of the same kit.
Also take note below that the Plane-Power alternator
has an included joggled small arm that attaches to the
alternator bracket and the starter, to give more
rigidity. The B&C dos not come with that
piece. They do sell them, but you would have to
ask and make sure the measurement is right to fit your
install, and then when you do install it, it's likely
to require you to also replace the bolt with a longer
bolt.
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Below are pictures of the tension
adjuster arm. Notice that the Plane-Power is
quite a bit thicker and stronger, ad it has a bent
joggle in it. This allowed the arm to fit
perfectly on my install. The arm was fairly
short, the alternator was snugged up near the engine
block, and all was well. The B&C isn't such
a good fit. The tension adjust bracket is
thinner, flexes a little, and comes too long for my
install on the RV-14 so I had to cut it shorter and
re-drill the hole in the end. That is in the
B&C manual. It would be nice if it fit
better, because even after cutting it, the arm was
longer and at a different angle altogether and ran
into my heater intake SCAT tube, so I had to RTV bond
a silicone pad to the SCAT to protect it from chafing
the bracket. Additionally, there is too much of
a gap on both of my installs, between the tension
adjuster arm and the alternator face. So they
provide you with the tensioner bolt and a thick
washer, but you end up needing 2 thick washers or
more, to get the proper fit. Had they joggled
the arm like Plane-Power did, it would be much better,
but, I think with their thinner arm, they would
probably need to use thicker material if they were
going to add a joggle. If these were the only
problems, the job would have been much better and my
impression would have been left much higher, but it
got worse.
What ended up happening is that the B&C bracket
for the Wide Desk, Boss Mount, Single Groove engine,
didn't end up fitting properly on my RV-14's new
IO-390, which is Boss Mount, Wide Deck, and Single
Groove. The U shaped boss mount bracket has one
round hole in it, and one oblong hole. I used
the straight tensioner arm as a guide to ensure my
alignment would be good. I STRONGLY suggest all
builders with B&C (and any other alternator for
that matter) actually check your alignment of your
main pulley and the alternator pulley. If the
alignment isn't good, you will wear, and risk breaking
your belts. If the belt breaks, and you have a
crank sensor like I do, you could end up disabling the
ignition system or anything else that is mounted up by
the ring gear. So always ensure you have good
alignment. Mine was off by something in the
neighborhood of .093-.095" (EDIT: It's actually about .060-.062 off) or so. If I lifted my
alternator to it's highest position and slid the
tensioner arm wrapped around the large pulley unit it
contacted the alternator pulley, it did NOT line up in
the groove on the alternator, but dug into the side of
the pulley. So, in order to get it to fit, I had
to file not just the round hole in the bracket to make
it oblong, but file the oblong hole even MORE
oblong. That will just be one more place that
you could end up with bracket movement in the future,
causing alternator belt issues. So I called them
and found out the difference between the bracket I got
(single groove) and the other bracket they offer (dual
groove). Turns out they shift the alternator
back about .130". I then went on to try the
install on my IO-540 as well. I figured that if
there were going to be an issue, it would be on that
engine since technically that was a narrow deck
engine. Sure enough, the single groove bracket
didn't fit that one either!!!! It was off and it
was worse than the IO-390!!
I decided to have them send me 2 of the dual groove
brackets so that I could try those
instead.
First the RV-10 with the IO-540. That one was
off almost perfectly the amount of .130", which is the same amount that the dual groove
bracket adjusted, so swapping my SINGLE GROOVE engine
to the DUAL GROOVE bracket fixed that install
completely. But what about my IO-390 that SHOULD
have been perfectly matched? Nope, that shifted
it too far, as expected, and now it was out of
alignment the other direction. I did ask B&C
to look into fixing this by coming out with a proper
fitting bracket, but to date I have not heard of any
progress on that front.
EDIT 3/28/2020: B&C Finally sent me some parts to try to fix the alignment issues. They "fixed" the issue on the IO-390, but after I pondered it, I wasn't thrilled with the fix, because that would mean the same alternator would no longer fit the IO-540. It turns out I was right, because when I went to fit the RV-10, it was now NOT good. Remember that previously I had to use their "Dual Groove" pully boss mount to make it fit. Well, it keeps getting more interesting. The Dual Groove must really be a "Single Groove" bracket, because I installed these alternators on my RV-10 and they all fit perfectly: The Plane-Power 60A, the Plane-Power 70A, and the BC460-H with the Boss Mount Bracket 403-301-4 (Dual Groove type that comes with the FK5400-1_Special install kit). The Standard FK5400-1 alternator install kit coems with the 403-315-2 Boss Mount Bracket, which does NOT fit my IO-540 nor the IO-390 properly, with the BC460-H. So it was back to the drawing board. The real fix is to come up with a new Boss Mount bracket that moves the holes .060-.062" FORWARD on the Boss Mount Bracket from what the 403-315-2 bracket is. OR, move the holes AFT .068-.070" of what the 403-301-4 Boss Mount Bracket has.
So the hands down winner of the bracket design here is
the Plane-Power. I'm not sure if it's just
because they're a smaller company, or because they
just don't know as much about the variety of Lycoming
engine cases as Hartzell/Plane-Power does, but
Plane-Power beats them badly on alternator bracketing
as far as I'm concerned. B&C's stuff looks
nice, but until they have the proper fit, and the same
strength, it's hard to walk away with warm fuzzies
about the upgrade from a bracket perspective.
EDIT 3/28/2020: Ok, so here I have to make another correction. If you read my update above, you see I tried all 3 alternators on the IO-540 and they all fit and aligned acceptably well. The Plane-Power alternators *appear* to align better, but that's because the bottom of the V-Groove is wider. In actuality, on the IO-540 it may have been off the width of a couple pieces of paper. Not 100% perfectly, but acceptably close. So I tried all 3 on the IO-390 and what I found there was that the Plane-Power 60A and the Plane-Power 70A both were off slightly on that plane, too. I estimate it would take maybe .036-.042 to get them to align properly on the IO-390. So that means that if everyone elses engines are the same exact form factor as mine, the Plane-Power alternators they're using are not aligned perfectly. The BC460-H remember is about .060-.062 off, so it's slightly worse...or .068-.070 with the other boss bracket. Either way, I think every builder should abosolutely verify perfect alignment on their IO-390 and even the IO-540, because an alternator belt breakage could cause them to be out of electricity, which would be a disaster on an electrically dependent engine. And, for Lightspeed Ignition users like myself who have a mini sensor or crank sensor up front, it could mean that the belt takes out the sensor, rendering their ignition immediately useless. NOT GOOD!
I have a whole section below dedicated to this bracket
issue, so if you keep reading you'll see exactly
what's up.
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