Pulley bore too big for shaft...

[Ryobiguy]

Finally I've gotten the cash to get my old south bend motorized, and the last of the McMaster Carr order came in: the countershaft pulley. Great - I tried fitting it on there and the bore (1.25") is about .125 too large for the shaft I've got. Off by a mile!
Well, the counter shaft was already in need of replacement... Is there some way I can wrap some shim stock around it to make the pulley fit (more or less) and use it just long enough to make a new counter shaft that fits right? I've got a variable speed motor, so I could run it very slowly... Is this just too stupid to even attempt? Should I just eat the cost and order another sheave?

[Mike Burdick]

Ryobiguy,

Gee whiz, talk about the ultimate “Catch 22” - need the pulley so you can run your lathe but you need the lathe to make the pulley! Oh…to be so near and yet so far. Don't feel bad, we've all been in your shoes at one time or another.

For the temporary fix, I’d do just exactly as you suggest with the shim stock and see what happens. You may be surprised!

Hmm...you need to make up about 1/8 inch. If you don’t have that thick of shim stock you can get some 1/16” brass stock at True Value, most hobby shops, or Ace Hardware. Or...try a beer can, or soup can or....

Oh - another option is to get a bronze bushing from 1 inch ID to 1-1/8" OD. Most bearing supplies will have those for about two dollars. If it fits a little tight you can always machine it down by turning the lathe by hand. Hey...don't laugh, somtimes a man's gotta do what a man's gotta do!
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[This message has been edited by Mike Burdick (edited 04-29-2005).]

[Your Old Dog]

I'd likely try Bondo. I'd coat the inside of the sheave with something for release agent, lay the sheave on something flat, stand the shaft up on end, center it as much as possible and then pour in the Bondo. When I was done using it I'd chip it out with a chisel and clean it up. I don't envy you position you're in but admire folks who find their way around these kind of obstacles ! What's that old phrase, "need is the mother of invention"

Don't overlook Bondo as used in body shops for odd jobs. My friend, an apartment manager, uses it to rework door jams after police bust them out on raids! Obviously, his unit is not exactly high rent district!

Brownells Gun Smithing sells a product called Acra-glass. It comes in kit form with release agent and is a great product but not available at the hardware down the street and it's more expensive as it's pretty neat stuff to work with.



[This message has been edited by Your Old Dog (edited 04-29-2005).]

[SGW]

I like Mike's bronze bushing idea.

[torker]

I'm stubborn enough to try this....as Mike says, you have the partial use of the lathe. Cut a piece of 1 1/8" ground stock the length to fit in the pulley. Center drill it on both ends, drill and tap for studs.
Get two pieces of 1" round, drill and tap one end of each for studs.
Cut slots in the ends of the short 1" pieces to use a big screwdriver to tighten the works together once it's all assembled.
Question....you have a variable speed motor....why can't you hook it up direct to do the machining? For that you could use an old flat belt any length you need and use a lace splice.
Russ

[This message has been edited by torker (edited 04-29-2005).]

[hoffman]

Maybe you could cobble something out of wood. Take the pulley to Lowes or Home Depot and start scrounging. That'd get it running and your first project could be a bushing. With wood you wouldn't have to worry about galling a shaft or the pulley.
Look in the PVC pipe section while your at it...

[darryl]

Easiest thing is to take some 1/16 thick material and wrap it around the shaft for one complete turn. It could be permanent if it fit right. I'd use a scrap of sheet steel of that thickness, that's probably laying around your shop in one form or another.

[J. R. Williams]

Ryo
Any good bearing supply place and many quality hardware stores stock what you need - a reducing sleeve made for the shaft and pulley combination along with a 'high' key.

JRW

[George Hodge]

I've had good results from wrapping copper or brass wire around a shaft to take up the space,cheap,can't hurt anything.