The Deuce Utility Vehicle (D.U.V.) Project – M35A2 Alternator Upgrade

The Deuce Utility Vehicle (D.U.V.) Project – M35A2 Alternator Upgrade A Shocking development One of the first issues noted on the DUV project was the lack of charging from the […]

The Deuce Utility Vehicle (D.U.V.) Project – M35A2 Alternator Upgrade

A Shocking development

One of the first issues noted on the DUV project was the lack of charging from the crusty old alternator. While we are planning 12v accessories in the future, the main point of this upgrade is to get reliable charging of our batteries in the original 24V military configuration.

If you’re looking to upgrade your old deuce alternator this would be a great, low cost DIY project coming in a bit under $150, while using an easy to find, off the shelf 24V alternator.

Deuce parts, on a budget

We chose the following parts for this DIY Deuce upgrade project:

The alternator and pulley cost $133 shipped. The 1/8″ flat bar was $4.99, the 5″ bolt was around $2 and the section of iron pipe would only cost $1.15 for the section used.

How to install M35A2 aftermarket alternator

  1. Bolt the lower hole on the alternator mounts right up to the stock mount.
  2. The top adjuster arm mounts to the top mount. With the lower bolt in place rotate the alternator into it’s final position.
  3. Measure the distance from the lower mount bolt to the alternator’s upper mounting hole.
  4. Make a the alternator upper mounting bracket from the steel bar.
    1. Cut the flat bar an inch or two longer than the distance needed (from step 3). You just need to make sure that the distance from the bottom hole on the bar is sufficient to drill a hole at the top end to bolt on the upper alternator mount.
    2. Mark and drill the hole in the steel bar for the upper alternator mount bolt
  5. Attach the flat bar mount bracket to the lower stock mount on the engine using the stock hardware
  6. Make and install the spacer for the upper alternator mount.
    1. Cut a 2.5″ length of steel pipe and clean up/debur the cuts
    2. Insert a 5-1/2″ bolt and washer through the upper hole on the flat bar mount bracket, through the spacer pipe, through the upper alternator mount
    3. Add 1/2″ washer, then 1/2″-13 nut – FINGER TIGHT ONLY
  7. Install the alternator belts
  8. Adjust belt tension, then tighten the upper alternator mount nut.

Wiring the M35 aftermarket alternator

The wiring is pretty straight forward.

  • The ground wire from the frame goes to the GRD bolt on the alternator’s upper post.
  • The hot line goes from the starter post to the red + on the lower post of the alternator.

Give’er some juice!

The final step is to reconnect the batteries.

Our aftermarket M35 alternator install results

The new alternator produces a solid 27.5 volts, right in the middle of the green section of the voltmeter.

That’s a first for this truck! For now, the benefit of a good charging system is a great morale boost for the DUV project. The toughest part is removing the old 60# alternator.

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Ammo for testing provided by Ruger / Polycase

Without the support of our ammo suppliers we would not be able to do nearly the amount of gun reviews that we do today. Polycase supplied their Ruger branded ARX defensive ammo for this review.

 If you like this, you might like our Slide Fire stock review

Where to buy Silencers?

You can legally purchase silencers online and have them shipped to your local SOT FFL, who will help you with the ATF Form 4 transfer process. Here are some links to trusted retailers who sell suppressors.

Quarter Horse Arms - machine gun from HMMWV

Jeff shooting the Quarter Horse Arms AR15 Full Auto from the Project Humvee Battlewagon

The Project Humvee Battlewagon

Gear Report acquired a real HMMWV (High Mobility Multipurpose Wheeled Vehicle) from the US Army for use as our official field and shooting range vehicle. We have already posted about some of our upgrade projects (Project Humvee Battlewagon article links) and have a lot of really cool projects on the way. Consider subscribing so you don’t miss any of the cool reviews as we post them.

Here is our Project Intro (link) and our list of HMMWV upgrade projects.

The Deuce Utility Vehicle (D.U.V.) Project M35A2

The D.U.V. project started with a fairly standard 1968 M35a2 two and a half ton 6×6 cargo truck. Commonly known

About Joe

Joe - Military Vehicle & Outdoor gear Review Specialist Having grown up in rural North Carolina and attending Western Carolina University, I have gotten accustomed to enjoying the outdoors. I was raised in an Army family with my dad being a career Master Sergeant, my uncle a retired Lt. Colonel and my cousin currently a Lt. Colonel attending the War College. Though I did not serve, I have the utmost respect for those that have and of course the cool toys they got to play with occasionally. My interests range from mountain biking, hiking, camping, car and truck builds and repair and of course shooting. I have also been known to shoot in the mid to low eighties at golf when challenged as well. While at Western I received my Bachelors in Parks and Recreation Management and my Masters in Business Administration. I was also a member of the track and field team, competing in the pole vault and the decathlon. My current athletic feats involve wrangling five kids, two cats and two basset hounds. We all have hobbies and one of mine has been car and truck builds. I have had several fun ones and some not so fun. My current vehicle, the mighty M35A2, will be the biggest one to date though. With plans for a quad cab, upsized wheels and tires, and accessories galore, it should be exciting for all.