Blank for the large pulley
Marking out and then cutting by hand a 3" round Ali bar, Took me 20-30 mins.
I gotta get a bandsaw!!
Method of making sure the rough-cut 3" blank is gripped paralell to the lathe ways, in order to face each rough-cut end smooth and true.
Turning the smaller section of the Large pulley
Center drilling the bore
After drilling the bore out to 1/2", I set up the boring bar to just reach through
Milling out some of the "meat" for the key way
Cutting out some more waste of the key
Turning the outer diameters of the 2 V's
Filing the key way
Plunge cutting the V shape with a custom ground Hss tool
The custom ground V shaped Hss tool
The large pulley with both V sections completed
Setup for milling the spindle-locking slot
The spindle-locking slot milled
The small pulley for fitting to the motor, I've just formed the larger of the 2 V sections.
The base with just the main pulley and fixing holes bored. The base is made out of 4" x 1/2" ali plate.
The motor pulley completed
Milling out one of the "ears"
Where the "ear" will fit
Milling out the othe "ear"
Ears mounted onto the base
Ears mounted onto the base (underside view)
Marking out positions of the motor mounting holes and pivot holes on the motor mount ( a piece of 1/2" x 4" x 5.5" ali plate )
Boring out the hole for the pulley on the motor mount
The chamfer turned on the motor mount
Making the brass bush for the pivot pin, drilling it 6mm
Using a grub screw the wrong way up in the base to mark out for the curved slot on the motor-mount.
Chain drilling the bulk of the curved slot
Holding the motor-mount with a F-Wrench to rotate it to smooth the slot with a 6mm slotting mill while keeping my fingers out of trouble
Milling down the motor mount for more clearance for the belt
Drilling and then tapping for the grubscrew on the large pulley
setup for drilling / tapping the smaller pulley for the grubscrew
the 2 pulleys completed
tapping the tension adjustment know
Knurled knob for adjusting the belt tension
The setup for drilling the hole for the spring loaded spindle locking pin.
Turning the spindle locking pin out of steel
The completed spindle locking pin mounted on the base
Showing the completed spindle locking pin mounted on the base
The completed mini-mill belt drive conversion
The completed mini-mill belt drive conversion, all taken apart
The spring loaded locking pin mechinism taken apart