The comparison photos below compare ACTs units to other manufacturers' high output offerings. It doesn't take any special training to see the major difference in construction. Alternators are subjected to MASSIVE amounts of heat, strain and vibration. The heavier duty your alternator internal components are, and the larger the alternator is, the better it will be able to dissipate heat. Furthermore, the more amperage the alternator produces, the larger the conductors need to be in order to physically transfer current without measurable loss. The following picture compares two rectifier assemblies. The one on the left came off of a well known brand of High output alternator. Notice the physically smaller anodized blue aluminum rectifier plate. The ACT unit on the right has a noticeably thicker solid laser cut copper rectifier plate, capable of dissipating much more heat, and conducting more current with less resistance. It may be hard to see, but the diodes in out rectifiers are much heaver, over .080 larger in diameter; 70 amp rated instead of 30 amp rated.
Internal components are just the beginning of what sets ACT high output alternators apart. Most midsize, compact, and import vehicles come equipped with very small alternator housings from the factory. Auto manufacturers have designed the smallest, lightest alternators possible in an effort to conserve weight and fuel economy. Modern import alternators are very efficient for their size, and cannot be easily improved upon like the simplistic domestic alternators of 20 years ago. The only way to increase the output on most small case alternators results in decreased output at lower RPMS. All other alternator companies rely on this technique because it is cheap and easy. This is why so many people who have bought high output alternators from other companies experience low voltage or poor performance at idle- Most times they have less low RPM output than a stock alternator!!
ACTs units are built completely differently. We have a full CNC machine shop in house, where we mass produce custom machined LARGE case units that have the same mounting specifications as the factory small case alternator. By going to a physically larger, late model efficient alternator design, we can achieve massive output (250+ amps) while still maintain brutal idle RPM performance. (Over 150 amps at 800rpm) In addition, larger internal components can be used which dramatically increases full temperature performance and durability through heat dissipation that can be in excess of a 400% improvement of small case units. The picture below illustrates the dramatic difference between out units, and a competitors "150 amp" offering on the left. With no surprise to us, the brand X units on the left barely mustered 5 amps at idle, with only 123 amps peak. Our unit on the right made 161 amps at idle with 268 amps at cruising speed- BOTH OF THESE UNITS FIT THE SAME VEHICLE. Notice the 1/0 included copper terminals for Positive and Ground cable connections. The grounding point is pressed directly into the alternator case to give the best possible grounding point. What good is making amperage if you can't get it to the battery??
ACT Alternator Comparison for 200 Series
