Help Timing Cover Section That Holds Serpentine Belt tensioner Broke off DT466 1999

Hi,
Any sugestions appreciated or leads to other forums.

I am no longer trucking or using my moving truck IHC 4700 double frame 210 HP DT466 5+1 36FT 9ft high box with granny attic commercially. I

am working as a building maintenance engineer these days part time.

200,000 miles on the chassis & engine.

I have been turning the truck into a large stealth RV. New brake rotors, rebuilt master cylynder, calipers, brake lines. Fresh water/Black water tanks. A few tiny windows insulation, tow hitch, stopping the rust, yada yada. Another few months figure would have it ready for summer 2015. Of course the Sherif Inspection to reregister as an RV.

I hate the chicken Coups.

Been thinking to swap out the 4.44 rear for a 3.54.

The Delco S22 alternator gave out.

Picked up two S22 160 amp rebuilds. 54$ each with shipping. I was not the original owner. Put 10,000 miles on it in 14 months. Paid 4,500. But a lot of labor and parts to make it safe and road worthy. All new tires. 6,000 watt generator: Emergency Brake shoes. You can imagine the time spent so far. The parts due add up. Even if you avoid the Dealer.

Little savings. Im old. But I still like to drive long distances for fun. Also want to leave Nebraska for good. Towing my car. Nice way to get started. My home is on wheels !

Ok hopefully you are still reading LOL. THE ISSUE

The tensioner bolt hole was stripped ! I think the last mechanic used epoxy ! Mirracle I dove it 10,000 miles. Bttom line. After chasing the thread. Picking up a longer Stud bolt to catch the unused thread. Using a wire wheel on the mating surfaces.......

The piece broke off as I pulled back on the tensioner to fit the new serpentine belt. If you are familiar with this engine... two bolts are available and close to this edge.

Machine a steel adaptor to fit these bolts with a plate extending past the original piece to put a bolt or Stud ?

I quickly found 1/4 steel brackets at Home Depot to make the alternator swivel on its lower 1/2 bolt.

Even was able to mount both alternators securely with a bit of adjustment to tension the belt. However the belt is a bit short. Ordered a pair of 60mm OD pulleys. $18.66 shipped. To replace the 87mm pulleys on the alternators.

The truck towing my car stays at 50-55

Can I do old school with this engine. No tensioner. Just using a shorter/longer belt and using the alternator travel to tighten it?

Thats how my Dodge D600 truck was LOL. Had that one over twenty years. Replaced the serpentine twice LOL.

I realize loosing the 60-70 degrees and wrap- around the alternator pulley might cause problems.

Such as alternator pulley slip and Belt slipping off. The Dodge had a big gas engine that did not vibrate much

Between IHC 8 groove and Ford 8 groove belts might find one to fit?

Over 2 million made DT466. EGR yada yada killing off this legend engine. Used in numerous truck applications.

Got to be a work around other than replacing the whole timing cover. Needless to say removal and re-installation of all these components and the cost of another timing cover. Also my feeling is that this is a weakspot on this engine.

Anyways. If I mount two alternators this would allow a high output inverter to be used connected to marine batteries separate from the starting running circuit.

Maybe another belt tensioner for a different engine using one of the other bolt holes near the original that is a bit shorter ? Assuming shorter. A kit I am not aware of?

Or somebody did it already and can walk me through?

Best John any info appreciated.