Kerry's bench drill aluminium pulley weld or replace

[striker]

Hi, just picked up a kerry's bench drill off ebay.. It has a four speed stepped pulley arrangement. I paid £16 for the drill so expected some work! Anyway one of the pulleys has the flange broken on the smallest (2") side it is roughly a third of the circumferance.. The pulleys are available in a section (1/2") but this is z section (3/8") Does anyone know where I might be able to get a replacement 2.3.4.5" stepped pulley from for 3/8" section belts. Another option would be to replace both the pulleys with A section but didnt really want to go to that expense..
Would this be weldable with those durafix rods or could anyone on here preferably close to teeside repair it for me for beer tokens! I have a small lathe so machining it back is no poblem.

Rergards, Paul.

 

[Paul.]

Most bearing / drive merchants will sell them, try Eriks, branches all over the country, they usually come pilot bore though so you will need to machine it to suit, expect to pay around £15 or so.
Here's one I found with a quick google
http://shop.marksman-ind.com/z-spz-stepped-pulley-406080mm-10994-p.asp

If you have all the broken parts it should be repairable, I would Tig it if possible

 

[striker]

Thanks Paul.. yeah I did google it and saw that but its only 3 speed in the z section... I havnt the missing part unfortunately and have no tig gear..could the flange be built up with weld?
if I could find someone willing to tig it?
Paul.

 

[striker]

Heres a pic of pulley

 

[Paul.]

Is that steel / cast Iron?, I was assuming it would be Ally when I suggested Tig, Either way it should be repairable, fabricate a piece to go in it, getting the inside face smooth is the important bit so you dont wear the belt out.
Having said that We had a drill with a similar broken pulley that ran just fine for years with a lump missing out of it, we just de burred the sharp edge and left it,

 

[striker]

Its aluminium Paul. Just not cleaned it yet...
I have a small lathe so can dress it up.. if I can find someone
to weld it, should I cut it off straightish and make a piece up to fit in/on
or could it be built up with weld?

 

[octo0072000]

Its aluminium Paul. Just not cleaned it yet...
I have a small lathe so can dress it up.. if I can find someone
to weld it, should I cut it off straightish and make a piece up to fit in/on
or could it be built up with weld?

are you sure it's alloy never seen rust on alloy ?

 

[bigegg]

I'd de-burr the smashed edge, and epoxy a large washer to the top as a backer
Then build up the missing part in epoxy putty, and machine to shape.

Will work whether it is cast iron, aluminium or pot metal.

Alternatively...
Is this the drive pulley? or driven?
If possible, make it the "driven" side - I, personally, only ever use the slowest speed - which means that particular size would never be used.

I'm guessing it's broken because someone's tried to hammer it off the shaft? I'd put a bit of copper grease on the shaft before replacing if it's ally - stops it corroding on

 

[striker]

Definately alloy.. not rust just gunge.
Epoxy and washer sounds good idea any recommendations for epoxy, jb weld perhaps?

 

[normspanners]

machine off the whole broken piece but leave a shoulder buy another matching single pulley machine a female match for the shoulder in the new pulley then bolt or rivet it to the original or if you can machine accurately and get the correct fit machine both with a slight taper and just press it on with loctite. ps warm the female before pressing. it would only cost a few £ for the new pulley and a little time!

 

[striker]

I cant get a pulley that's the problem. Good idea about pressing single pulley on after machining back though!

 

[bigegg]

Definately alloy.. not rust just gunge.
Epoxy and washer sounds good idea any recommendations for epoxy, jb weld perhaps?

Isopon p38 car body filler - could also be used in place of the epoxy putty, just not as well

 

[MattF]

I cant get a pulley that's the problem. Good idea about pressing single pulley on after machining back though!

Use the method Norm described but just taking off the outer side of the pulley. You only need a 2" diameter aluminium disc to make a new outer for it, which you can easily taper off on the internal face when it's fitted.

 

[normspanners]

http://www.ebay.co.uk/itm/RDGTOOLS-...FOR-V-BELTS-/350450410278?hash=item519878e326
or
http://www.bearingboys.co.uk/SPZ050_1_Aluminium_V_Pulley_-96918-p

 

[jordan1]

Use Belzona or Devcon Titanium putty, what the industry use for repairs.

 

[striker]

Thanks for all the advice everyone..going to try the putty and washer idea. I dont seem to have enough meat to machine a recess and spigot as its a 1" bore through the middle. That leaves about 4 or 5mm wall... if it fails then I will get a pair of A section pulleys from chronos and fit larger section belt.. about £45 all in..
I will post pics of bodged I mean repaired pulley when complete.
Thanks again, Paul.

 

[striker]

Well I got it fixed. I used jb weld and made a 2" washer from 16g aluminium. Seems ok...machined it back on my lathe...Only time will tell I suppose!

 

[MattF]

That looks like it should do fine. Tidily done.

 

[bigegg]

very nice