Is this pulley repairable?

[jimbo84]

As the title. It was fitted to my Boxford when I bought it. It has had some kind of JB weld type repair done to it (badly, you can pick it off easily). The pulley wasn't sat true and square on the shaft so it wobbled badly, not so bad on the slower of the two speeds but quite frighteningly on the faster speed.

Split and cracks all over the place. Is it possible to fashion some kind of repair to it or is it too far gone? It's double grooved and the bigger side measures just over 8 inches at 211mm and I haven't come across any replacements online at that size.

I damaged this one getting it off the shaft. I'm thinking of filling the well area to fix it up, is there a better way? it's a 4 step pulley.

 

[maroon]

Should be able to weld that what's the cast made of?

 

[Barking Mat]

How much do they cost to replace / are they available ?

 

[The_Yellow_Ardvark]

Are spares easy to get hold off?
What is it made from? Steel yes it can be welded.
Alloy you will some more skills.

The big issue is the Mirco cracks you cant see, the heat will open them up.

 

[Gareth J]

I've never managed to get to any level of competency with aluminium. So, in situations like this, I try to bolt on some steel and get that to do the job. Specifically, I'd remove the damaged hub, make a new hub out of steel, with wings on it to spread out to the webs of the cast aluminium with this then bolted/tapped to each other. Then, with the hybrid/abomination trued in the lathe, rebore the steel hub.

Better if you could get someone to weld it though

 

[Redsailor]

I would remove the entire centre section by cutting it through across the four lightening holes. Then then rough machine a new centre section and bolt it in place, then set it running true and bore out the centre and cut a new keyway. The small, damaged part on the rim could be removed and repaired with plastic metal and filed to shape.
Unfortunately, you would have to find a working lathe first.

 

[Chippie]

Would it be more appropriate to make a pattern and get a new one cast?

 

[Barking Mat]

Would it be more appropriate to make a pattern and get a new one cast?

Turned up on a lathe easier ?

 

[Brad93]

is it aluminium or cast iron

 

[not done it yet]

I would remove the entire centre section by cutting it through across the four lightening holes. Then then rough machine a new centre section and bolt it in place, then set it running true and bore out the centre and cut a new keyway. The small, damaged part on the rim could be removed and repaired with plastic metal and filed to shape.
Unfortunately, you would have to find a working lathe first.

A good idea, so yes it can be repaired. A shame the cracks go out to the holes, which may make it a simpler/safer job to just make a replacement.

Without those cracks I would just machine up a centre piece and fit it, to directly replace the piece removed. The cracks may make it less safe in the future, meaning a new one might be preferable. It’s not exactly much harder to make the whole thing.

A new ally pulley is possibly available from the net for not too much money, needing only the boss to be modified? I have a string of simplex ally pulleys to choose from. Bought as a job-lot at a sale many moons ago. I’m guessing this is a duplex example? (edited)

Edited further to suggest a sleeve, of sorts, around that second broken pulley boss before resorting to filling the void with a filler.

 

[brightspark]

has the op another lathe though or access to one

 

[jimbo84]

Should be able to weld that what's the cast made of?

It's alluminium/some kind of alloy

How much do they cost to replace / are they available ?

Haven't been able to find anything like it. It's double V'd of different sizes and just over 8 inches diameter.

Are spares easy to get hold off?
What is it made from? Steel yes it can be welded.
Alloy you will some more skills.

The big issue is the Mirco cracks you cant see, the heat will open them up.

Haven't been able to find anything suitable. It's some kind of alloy/aluminium

I've never managed to get to any level of competency with aluminium. So, in situations like this, I try to bolt on some steel and get that to do the job. Specifically, I'd remove the damaged hub, make a new hub out of steel, with wings on it to spread out to the webs of the cast aluminium with this then bolted/tapped to each other. Then, with the hybrid/abomination trued in the lathe, rebore the steel hub.

Better if you could get someone to weld it though

I like the idea of this. possibility of getting a smaller pulley of the correct bore and keyway and bolting that onto it somehow I guess.

I would remove the entire centre section by cutting it through across the four lightening holes. Then then rough machine a new centre section and bolt it in place, then set it running true and bore out the centre and cut a new keyway. The small, damaged part on the rim could be removed and repaired with plastic metal and filed to shape.
Unfortunately, you would have to find a working lathe first.

I have access to another lathe, not sure I'm brave enough to use it, it's about 15ft long, only used to hobby/amateur sized lathes.

Would it be more appropriate to make a pattern and get a new one cast?

This would be prohibitivly expensive I guess, I'm on a limited budget for the lathe just being a hobby.

is it aluminium or cast iron

It's aluminium/some kind of alloy.

 

[Gareth J]

I like the idea of this. possibility of getting a smaller pulley of the correct bore and keyway and bolting that onto it somehow I guess.
just being a hobby.

If you did it that way round, you'd have to be good at getting it all true in all the directions. If going that way, I'd make one part fit into the other, like a top hat section, in the big lathe. So that you only have to get the bits true individually, ready to mate together and hopefully still be true.

 

[6ply]

No spares on eBay.... maybe someone is hogging them? I have a few spare pulleys, some are 7". What exactly do you need?

 

[Agroshield]

I would remove the entire centre section by cutting it through across the four lightening holes.

As you say, bore out the centre and replace with new material (possibly machined from a solid round). Shrink fit the two together and dutch key at the joint.

If you machine the new bit before removing the damaged bit, it would be possible to use a mill to bore the rim of the old pulley that is retained (thus not needing a second lathe).

If you were really desperate, you could rig up a temporary drive to the existing lathe (electric drill hot glued to the end of the spindle), strap the rim to a faceplate and bore on the lathe itself.

 

[minimutly]

As the title. It was fitted to my Boxford when I bought it. It has had some kind of JB weld type repair done to it (badly, you can pick it off easily). The pulley wasn't sat true and square on the shaft so it wobbled badly, not so bad on the slower of the two speeds but quite frighteningly on the faster speed.

Split and cracks all over the place. Is it possible to fashion some kind of repair to it or is it too far gone? It's double grooved and the bigger side measures just over 8 inches at 211mm and I haven't come across any replacements online at that size.

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I damaged this one getting it off the shaft. I'm thinking of filling the well area to fix it up, is there a better way? it's a 4 step pulley.

View attachment 372665

3 step now....

 

[Dilkris]

No spares on eBay.... maybe someone is hogging them? I have a few spare pulleys, some are 7". What exactly do you need?
View attachment 372692

I just have to ask - how did you end up with all of these???

 

[not done it yet]

I just have to ask - how did you end up with all of these???

He’s in Dorset, so I might guess the origin of at least some of them as the great dorset steam fair.

 

[6ply]

I just have to ask - how did you end up with all of these???

From working on various machines, making modifications, etc.

 

[6ply]

He’s in Dorset, so I might guess the origin of at least some of them as the great dorset steam fair.

Not the pulleys, but I did buy some aluminium stock.