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K20 alternator relocation A/C P/S delete

K20 alternator relocation A/C P/S delete

Posted by Kym Allen on 18th Aug 2020

Why do we manufacture our alternator relocation kit?

We decided to create this kit, knowing that in many K series applications, the layout of the ancillaries does not leave a lot of room for upgrades to the engine. Without this kit, fitting a set of individual throttle bodies to a K series engine is pretty much impossible due to the large water pump housing.

Our kit creates more room for custom / bigger inlet manifolds by removing the material used to hold the power steering/auto-tensioner pulley. Additionally, if you are trying to put a K series engine in a different chassis, space becomes a significant concern where bonnet and light clearance can be a big issue.

We wanted to make one of the strongest and best-looking kits on the market. Most of the other relocation kits on the market use a single bolt method to hold the alternator, which is insufficient to cope with the forces generated in the alternator itself.

We have over-engineered the alternator bracket to ensure the bolts won't shear, leaving you trackside in a sticky situation and having to extract and replace the bolt that has snapped.

What are the benefits of running our relocation kit?

All our relocation kits come with a lifetime warranty on bolt breakages; that is how confident we are in our design. We have chosen to manufacture this kit in billet 6061-T6 aluminium, and the pulley slider in 316 marine grade stainless steel with a high-temperature GKN sealed pulley bearing. We also supply a high quality seven rib belt that ensures no-slip, even higher than stock RPM.

Absolutely no corner has been cut in this kit's design and manufacturing process, meaning it is potentially the most robust and most reliable kit on the market to date.

We supply this kit with an anodised or polished finish, making it stunning in your engine bay! Reliability was the number one aim, but we also wanted to make sure it was appealing and made for a clean looking engine bay.

Power steering and air conditioning in a track-based or fast road car aren't necessary. We wanted to make a kit that focuses only on what you need, simplifying your engine setup, which helps with reliability as there is less to go wrong. Removing these parts allows for easy K series engine swaps into other chassis without much room.

For example, putting a K series engine into an EF chassis is incredibly tight on bonnet and headlight clearance which is no longer a problem with the use of our kit. Trying to fit an aftermarket intake manifold or throttle bodies to a K series engine comes with the challenge of working around the top pulley on the engine. Still, all of the headaches are removed with our kit, leaving plenty of room to work and install aftermarket parts.

When designing this kit, we wanted to ensure that the design was simple and installation and maintenance were made as easy as possible. We have provided everything needed to install and run our kit, from the belt to every nut and bolt, meaning when it turns up, it is a simple, straightforward fitting procedure. We have even included a sheet containing bolt size and placement, keeping installation easy.

Can I keep my P/S and A/C?

Our kit installed removes the ability to run the OEM power steering and air conditioning units. Whilst these are not necessary components, especially on track-focused cars, some people like the feeling of power steering to help move around the pits and whilst parking.

The best way around this problem is to fit an aftermarket electric power steering unit in the car, allowing the use of our relocation kits but still retaining easy manoeuvring at super slow speeds.

Keeping air conditioning in the car would be a bit trickier. Still, with aftermarket air conditioning units on the market becoming more readily available, it would be possible to run an electric air conditioning compressor, which could be located away from the engine freeing up space in the bay.

How do I convert to electric P/S?

Converting to electric power steering comes with its challenges. Still on the market today, you can find kits that allow you to use an electro-hydraulic system from a Toyota MR2 and provide you with 90% of what you will need to perform the swap. Removing a hydraulic system and switching to electric will allow you to use our kit, retain OEM steering feel, and gain up to 8WHP through the loss of parasitic drag the OEM hydraulic steering drains from your engine.

Does this kit come plug and play?

This kit comes with everything you will need out of the box, and we have taken the time to include every piece of hardware necessary to fit this kit, including the belt and pulley (with bearing pressed in and held with circlip). Furthermore, a complete diagram of the kits bolt layout and size ensure mistakes will be hard to make when installing our product.

The adjustment on the tensioning pulley is very accessible from the top of the engine, meaning future belt changes and maintenance will be a quick and easy task.

How did we design and manufacture the kit?

After realising that the kits on the market have a crucial design flaw, we decided to start designing our own. We started this process by firstly scanning a K20 Honda engine using our high-end Creaform Handy scan 700 Laser Scanner. With the engine 3d scanned, we could then import that data into our CAD software to start designing and overcoming problems.

The main concern when designing this kit was ensuring that the alternator would be held firmly enough to ensure there would be no flex in the shaft under heavy load and high RPM.

Once we had created the main design, we could start to ensure the tolerances were going to be as tight as possible, leaving a super clean fit and no installation problems. We wanted to make this 100% plug and play, which meant we had to decide what hardware would be best to keep the kit together.

With bolt size and thread pitch decided and the kit designed in our CAD software, we got a test kit sent to machining ready to put into testing. However, before any testing could commence, we had to decide on what belt to run the pulleys on as we ideally wanted to find one belt that would fit all variations of the K20 engine.

Finding one belt was not too hard to achieve, as, during the design process, we ensured a good level of adjustment on the tensioning pulley slider. Finally, we had to decide on bearings that could hold up to heavy use conditions and purchase a bearing press.

Once we had all the bearings pressed into the pulleys and held together with high-quality circlips, we could then start testing. We have tested this kit on our cars whilst driving in all conditions, heavy loads, and long journeys whilst also ensuring the kits go through many heat cycles and no play incurred in the bearings.

With adequate testing done and nothing but positive results, the final step was to make the kits look the part, splitting the kits up and sending some off for anodising. Then hand polishing the raw aluminium kits, ensuring that our products look stunning for installation.

To have a look at our k20/k24 alternator relocation kits, click on one of the links below:

Polished Silver

Anodised Black

Not sure whether it will fit your application? Give us a message on our contact form; we are more than happy to assist you and find the correct product for your application! Alternatively, leave us a comment below with your thoughts or questions.