Thanks for the kind words rklopp, a little belated sorry.
Hi guys, wow where does the time go? I haven’t posted anything on my projects since February, I have been busy with other project and more than the usual customer jobs this year. I’m still hoping to get this project finished up by springtime.
Not that I haven’t been in this shop (I am most everyday) I just haven’t been able to spend any time on the Pacific.
I only have a couple outstanding items to finish up before I can take it down for paint and some brown stuff. One of these items is the belt pulley, the engine doesn’t really need a belt, pulley but with the crank shaft sticking out there it was just begging for one. I couldn’t find any suitable castings for one so I decided to just make one from scratch.
I liked the size of the Mery pulley but I really wanted a six spoke pulley, the Mery pulley only has five spokes.
The center was made from a slice of 6”cast iron round bar and the rim from a piece of 5” Sch. 40 pipe.
Here the first side of the center is turned.
Then flipped around and the other side turned. The hole for the crank shaft is drilled under sized and will be bored to fit after the pulley is assembled.
The pipe is bored for a.005” to .006” interference fit, the width is left a little long so that it can be squared up after assembly.
Using soft jaws to hold the center the spokes are machined.
All the spokes have been machined and ready for some fillets.
Using a 3/16” ball end mill and a Z Level Finish tool path, the fillets were machined on both sides.
Here are the parts ready for assembly.
The center is taking a swim in liquid nitrogen; the all thread was added for use as handle.
The rim was heated to 400 degrees f using a rose bud and checked with a temp stick. The bronze spacer was machined to keep the center in the middle and square. Heating the rim only probably would have worked but using the LN2 gave me an extra .02” of wiggle room. The center dropped right in.
I was very happy with the results everything ran nice and true, within a thou or two.
Once brought to proper width the outside was turned to size and the crown added. Using my CAD software I created a step and cut chart to cut the crown. Working from the center out, each side was roughed out. In this picture the finish work has been started.
After the lathe work was completed the tapered key-way was put in using the same tapered bushing and broach that was used on the flywheel. I didn’t take any pictures but a proper Gib head key was also made.
Here is the pulley installed on the engine, I’m quite pleased with how it turned out. When the finish work is done it will get a small fillet where the rim meets the center, using some sort of filler.
Well hopefully it isn’t another nine months before the next update.
Thanks for checking in.
Dave