MetalworkingFun Forum

Hello johnnyc14. I didn't want to bother you with the measurements, because you never know when someone is busy. All I really need are the 2 outside diameter measurements of the motor pulley. And thanks again for your help.

Mark

Hey Mark, I finally found the time to get those pics and measurements. The OD of the smaller pulley is 2.040" and the outer one is 3.490"









John

Thanks John. That's exactly what I needed. The pics definitely clarify things as well.

Mark

After getting the critical measurements from johnnyc14 (thanks again John) I drafted a precision blueprint of the dimensions:



There is a pulley here somewhere.....



I couldn't chuck the rough piece, so I drill pressed it and mounted it on a bolt to turn down one end:



After that I was able to chuck the piece and drill the hole to clear the boring bar that was made for this project. Boring Bar

Not sure what happened there but I'm having a hard time typing after inserting a link, it wants to continue to underscore everything after that. Sorry guys, on to the post.

I didn't take a picture of actually boring the hole because I was concentrating so hard on trying to get it right on the measurement, I forgot.



After the boring procedure, the large diameter was cut:



Then the small size with some Dykem for the old eyes:



The part was slotted with a parting tool and more markings were made:



After much research, I realized that pulleys aren't just a simple part, and that different angles are used for different belt sizes and pulley diameters. The angle of the existing pulley on the machine is 34 degrees included as far as I can tell. The pulley that was made here is quite a bit smaller, so I used 32 degree for the larger one and 28 degree for the smaller one. The small one has a real tight radius for the belt being used. I don't know if these are the correct angles to use, but I hope they are close.



Cutting with cotton swab dipped in kerosene:



Pulley almost complete and mounted on shaper ready to cut keyway with inside keyway cutter. Shaper keyway cutter



Keyway is finished and it cut beautifully:



Not all is perfect in amateur land though, and I ended up drilling the set screw hole a little off set. But like my friend Kent and I always say when something is not perfect but will work "What's it gonna do....Not work?



Well that's it for now guys. I can't believe what has to happen to make a simple pulley, but I learned a lot. This is the first complex (to me) part I ever made on a lathe and I'm happy with the way it turned (ha ha ha) out.

Mark

Nice work Mark.

Thanks Mayhem.

Very nice Mark  
 
DaveH

Good job!

Machinery's Handbook has all of the angles for pulley design if you wanted to verify your work.

Nice work. BTW, I usually drill & tap the set screw a fractional size smaller than the key way. I.E. #10 (3/16") for a 1/4" key. Helps to compensate for being a little off center.