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craynerd`s X2 belt conversion
raynerd:
Well I`m so pleased - I`ve managed to finish the main pulley for the belt conversion - key-way is cut and fits like a glove, no movement at all. I need to drill and tap the grub screw yet but I`ll do that later when I have the base plate so that I can ensure the position aligns with the spindle lock hole. I know this is probably run of the mill stuff for you guys, but making this, and more impressively actually having it fit has been a real confidence booster. I can`t actually believe I have made it! I can`t see the smaller pully being too much of an issue after turning this one - then it is on to the base and motor plates.
The only error I made was taking the V groove a little low on the larger pully but I`ve been looking at it and I really don`t think it`ll make a difference. I was concerned the belt may rub but it is slightly elevated anyway.
The keyway was a pain. It took me a good few hours and I resorted to going to RDG tools, buying a file the correct width that fit the collar with the machined original key way. Once I had this it was much easier as it was just a case of filing straight along the line I had already milled a little to get it square.
I am sad enought that I made a video :lol: :doh: ....enjoy
Chris
websterz:
--- Quote from: craynerd on May 27, 2009, 06:55:10 PM ---Well I`m so pleased - I`ve managed to finish the main pulley for the belt conversion - key-way is cut and fits like a glove, no movement at all. I need to drill and tap the grub screw yet but I`ll do that later when I have the base plate so that I can ensure the position aligns with the spindle lock hole. I know this is probably run of the mill stuff for you guys, but making this, and more impressively actually having it fit has been a real confidence booster. I can`t actually believe I have made it! I can`t see the smaller pully being too much of an issue after turning this one - then it is on to the base and motor plates.
The only error I made was taking the V groove a little low on the larger pully but I`ve been looking at it and I really don`t think it`ll make a difference. I was concerned the belt may rub but it is slightly elevated anyway.
The keyway was a pain. It took me a good few hours and I resorted to going to RDG tools, buying a file the correct width that fit the collar with the machined original key way. Once I had this it was much easier as it was just a case of filing straight along the line I had already milled a little to get it square.
I am sad enought that I made a video :lol: :doh: ....enjoy
Chris
--- End quote ---
You are sailing right along the learning curve Chris. I have spent weeks doing hands-on training with guys who didn't come along as quickly as you are. Definitely something to be proud of!! I guess some folks are just born metalworkers. :beer: :thumbup:
kvom:
I made a pulley as a class project last summer. I am wondering why you needed a form tool. I used the parting tool with the compound set to the taper angle for the sides.
I was fortunate that at school we have broachs and an arbor press to cut the keyways. Filling one would drive me nuts. :hammer:
raynerd:
Cheers Webby!
Kvom - you are right, in retrospect I didn`t need a form tool. I`m new to this and I have copied most of the build from Tim (see SpudEvans belt conversion) and it looks like his lathe compound slide won`t set at 17deg, there is something in the way, I don`t know what lathe he has. So he made a forming tool, I saw what he had done, it worked, I understood so I copied. I did use a parting tool to take away some of bulk and bring to depth, now I realise I could have used it to form the sides! Anyway, you live and learn. It worked!
What is an arbour press?
kvom:
I don't mind answering the broach question. They are used to cut keyways in shaft holes, such as for pulleys. You have a round sleeve the same diameter as the hole with a square cutout the same width as the key. Put the sleeve into the pulley. Then the broach, a tapered, rectangular cross-sectioned, serrated cutter that fits into the slot, is pressed down (arbor press!) cutting the keyway.
I have never done it, but it would seem to me that a ground HSS tool held in a tool post on a lathe ought to be able to cut a short keyway as long as the setup is rigid enough, and sufficiently small cuts are made..
I have a small 1-ton Palmgren arbor press bolted to my workbench. It is useful for press-fit parts the size we use for models. Of course, the jaws of a milling vise can also act as a press. If I were to do it again I would get the 2-ton model. That said, neither of these would likely be capable of broaching in steel. The press at school is a big Dake model that is probably 15-20 ton.
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