03-01-2015, 09:15 PM
I had recently joined a snowblower forum to learn more about them before I'd sprung for the two new Ariens machines. In one of the subforums welcoming new members was a post from a new member who was looking for an obsolete pulley for a 30 year old Honda machine. It seems her husband was using it and it just stopped. They put it into a repair shop who couldn't find a replacement, so I offered that if I couldn't fix it I'd just make one.
When I found out the pulley was a weldment of at least two pieces, one of which is a splined hub. Because the pulley was still with their machine in a repair shop, it was unknown what materials were used in making it. A member Honda technician suggested it might be aluminum. As it turned out, no one could find a NOS pulley anywhere, so she collected it and sent it to me. It's a stamped and welded together sheave with a welded in splined hub. The weld at the sheave to hub had failed.
Yesterday (so not today's project) I grabbed a piece of 10" x 10" x 1/2" thick aluminum, sawed and squared it up 7" square. Then I circular milled the plate about .100" (2.5mm) deep to accept the better edge of the sheave's OD. The hub showed one small band of unplated (I think Honda had it zinc chomate plated) metal as the center of it's OD, so I milled a Ø 1.104" counter bore another .040" (1mm) deep to center the hub axially. A Ø .500 reamed hole in the center accepts a shoulder pin I made, and a Ø .530" diameter under the 1" head places the spline's monir diameter concentric to the OD of the sheave.
All the pieces:
![[Image: IMG_20150228_175106709_HDR_zpshwtyimzq.jpg]](http://img.photobucket.com/albums/v466/kenm10759/Dads%20shop/IMG_20150228_175106709_HDR_zpshwtyimzq.jpg)
The locating pin and the center relieved clamping washer, both made from 4140HT, and the 5/16-18UNC SCHS to clamp the splined hub to the plate:
![[Image: IMG_20150228_175416264_HDR_zpscverlggh.jpg]](http://img.photobucket.com/albums/v466/kenm10759/Dads%20shop/IMG_20150228_175416264_HDR_zpscverlggh.jpg)
Partial assembly, the clamping arbor not pulled in to seat yet. A couple of clamps over the plate and sheave with keep those together for welding:
![[Image: IMG_20150228_175225423_zpsqqkxxd0k.jpg]](http://img.photobucket.com/albums/v466/kenm10759/Dads%20shop/IMG_20150228_175225423_zpsqqkxxd0k.jpg)
My friend Jennifer will be welding it up for me in a day or two and I'll ship it right back out to Buffalo NY.
When I found out the pulley was a weldment of at least two pieces, one of which is a splined hub. Because the pulley was still with their machine in a repair shop, it was unknown what materials were used in making it. A member Honda technician suggested it might be aluminum. As it turned out, no one could find a NOS pulley anywhere, so she collected it and sent it to me. It's a stamped and welded together sheave with a welded in splined hub. The weld at the sheave to hub had failed.
Yesterday (so not today's project) I grabbed a piece of 10" x 10" x 1/2" thick aluminum, sawed and squared it up 7" square. Then I circular milled the plate about .100" (2.5mm) deep to accept the better edge of the sheave's OD. The hub showed one small band of unplated (I think Honda had it zinc chomate plated) metal as the center of it's OD, so I milled a Ø 1.104" counter bore another .040" (1mm) deep to center the hub axially. A Ø .500 reamed hole in the center accepts a shoulder pin I made, and a Ø .530" diameter under the 1" head places the spline's monir diameter concentric to the OD of the sheave.
All the pieces:
The locating pin and the center relieved clamping washer, both made from 4140HT, and the 5/16-18UNC SCHS to clamp the splined hub to the plate:
Partial assembly, the clamping arbor not pulled in to seat yet. A couple of clamps over the plate and sheave with keep those together for welding:
My friend Jennifer will be welding it up for me in a day or two and I'll ship it right back out to Buffalo NY.