I finally got a pulley the right size for my alternator.
The Alternator is a 140 amp from Summit, and it came with a 2.3" pulley. Well, It sort of worked. I could not get enough grip on the pulley to be effective. After I switched on my fans, the load would smoke the belt. I asked around and I found my local Checker had a box of pulleys. I sifted through and found 2 2.9" pulleys. They just let me have them.
Went home swapped pulleys and it worked better, but after some hard drivin' I smoked the belt and limped home. Fed up with not enough surface to grab, I bought a 5" pulley from Summit. As I was putting the 5" on, I noticed another alternator I had on the bench. It had a 3.6" pulley! Good thing too, I wasn't looking foreward to having a 5" pulley and it's underdriven characteristics. The 3.6 does not smoke the belt, but did require a slightly larger belt.
I guess the leson I learned is to look, the right size is out there... somewhere...
In the pictures are the pulleys. First is the 3.8" and then the 3.8" and the 2.3" next to each other. Last is the 2.9" next to the 2.3"
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