Alba 1A Shaper Reassembly Part 7A: Turning a Custom Motor Pulley

[Music] hi I'm Everett and welcome back to the shop progress on the shapers been a bit slow the last couple weeks here between well some of the family and friend projects coming in and we've had family visiting one of the projects was that set of rollers for the hose reel that's the last video I put up but some of the projects I just had to get dealt with done quickly out the door so all I did was just take pictures in the process I'll put a couple pictures up here of what they were one of them was this one it's a sign post and for my buddy's wedding they were using it for part of the decoration it's a chunk of exhaust pipe welded to a disc from a disc cultivator and it came out okay it was just a bit tricky because it was an unknown carbon steel or alloy steel probably disc and it'll stay some sort of unknown stainless exhaust pipe so that was a bit tricky to weld as well there was a couple brackets needed for a tent so I brought one of the brackets home and I wanted making a coupling brackets for it and as well there was my mom and dad came to visit and my mom's still involved with the local leaving and fiber arts guild in her town so they needed some of these things called Hetal hooks these things are used for setting up a loom and you know running strings here there and everywhere and they have to be really fine with a hook well it turns out that windshield-wiper stiffeners were the perfect size to bend and got a hook in and jam into a handle so we made a bunch of those and finally my Uncle Mark needed a Lovejoy bushing adapted to the front end of this one motor that used to work on a hot tub so it had to we had to cut a keyway and make a few adjustments on some things and so I made the keyway it's 1/8 inch wide and put a little flat on the other ninety degrees off of it so that it grabs on the ninety degree offset set screw so you so that's when I've been up to the last little while and needless to say the shaper kind of got put on pause for a while so anyway we're now back at the shaper again and what we need to do now is make the pulley to go on the motor now the pulley that came with the motor was just a single you know single groove hardware store variety one the motors not original it's the original one was a 440 volt 3-phase unit this one's 125 single-phase and so this would this is close to the right size for the low-speed but I want to have both speeds on the motor because I have both speeds in the transmission so that gives me the four original speeds the thing is the motor that came rate on this thing originally was 960 rpm at 50 Hertz the motor I have is 1725 rpm so very thankfully Neil from his channel Neil 9 he's got a shaper very similar to mine and he did a bunch of work to rebuild and work on his but his motor is still original which was really handy he was kind enough to take some measurements for me and send them to me and so what I did was I did the math and again I converted from the metric he gave me to imperial because that's what I have for tooling but yeah what I want to doing was going to the CAD program and that's where we go we got ourselves a diagram for a pulley all the measurements being a smaller pulley and double-checking the B pulley Shiv basic dimensions the 34 degree included angle between the walls so with that I also needed a piece of material it just so turned out that this lump of scrap that I had in the bin there from some well again from scrap metal bin somewhere I'll be able to get my double pulley out of this unit holding it's going to be a little bit of a trick but that's okay we'll figure out a way to do it now if I were starting with a larger piece of stock I would probably hold it by the bigger end in the truck and work this end first so it's going to be a little bit awkward as far as working around it and machining it but this is the way we're going to have to do it I have plenty of extra material on the smaller face here because you know it's only coming up to about there so I'm going to grip it on this side and then we'll support this back in here when we're doing anything really serious so now it's time to center drill this and start drilling it can start by Center drilling now because I want to get this ball started straight that is a 11 30 seconds short carbide drill bit [Music] so that was a carbide bit drill bit now we're going to use a high speed steel drill bit now there's no real reason to have to make this a through-hole the part itself is just under two inches long and well the hole is now drilled two and a half inches deep a little over I also as far as drilling and some of this works concerned I don't have a thirty 9/64 drill bit I do have a thirty seven sixty fourths but not a thirty nine sixty fourth so we're gonna use this to start with go from there let's do two twenty see how it likes it all right now the hole we just drilled is actually 2 and 5/8 deep so that means that as far as not bottoming the reamer out I should be able to just go in two and a half inches and not have to worry about bottoming it oh man I tell you sometimes sometimes it's hard to get time in the shop like you hope I kid you not this piece has been chucked up here with the hole drilled in it for almost a week and yeah so I finally have a chance to get back at it last time when I was at it last time we were at it the hole was drilled up to thirty seven sixty fourths it's the next biggest drill but I have before I hit five eighths I need a nice clean 5/8 hole to fit on the shaft of the motor so what we're going to do is we're just going to do a couple quick boring passes with this dinky little boring bar it'll probably scream like a banshee but such as life right now it's at 577 for a bore size I'm just going to take four teeth out of it and that'll leave us another eight thousand roughly in that neighborhood [Music] [Music] I don't know if you can read it there says 615 650 and a half 614 again digital calipers especially the cheaper ones are you know close so that still gives us about ten thousand source ordering with my whole is just a hair over two and a half inches deep so if I just go two and a half inches in with my reamer I should be safe lots of Lube and here goes yeah I think that should have it however proof is in the pudding I don't have any sets of gauge pins but I do have a 5/8 inch end mill oh and if I push it in quickly and release we're starting to compress air so I'll call that close enough I like it what I'd like to do now is chamfer this and with a little wider Shafter than usual that way I can use the live Center and this end to support the material as they start machining the two features here that the two grooves at their right diameters so I'll get set up for that so I've set the compound to well basically 30 degrees which makes a 60 degree included angle which will work for the live Center [Music] now for what it's worth this little taper here this little chamfer is not going to cause a problem to to this thing as far as its functionality it's certainly not going to cause a problem as far as being you know shaft contact or for cutting the cutting the key way with the broach so it'll be fine the diameter here it needs to be two point six one inches is roughly 2.74 at the moment so we need to take about a hundred and thirty thousands off of it uh yes the bird's nest I'm probably not using the ideal geometry for this material at the moment but such as life just try not to kit shrapnel down your shirt two point six oh nine and a half is what the dialer indicator says so take it for what it's worth so that journal outside diameter is complete give me a moment here I need to see what I can find for tooling to be able to cut in here I don't have a whole lot of left left hand cutting bits I'll see what I have well I didn't have a whole lot for left hand turning tool folders so what I do have though is this one here comes from a set that my buddy Cal gave me a while ago because of the proximity to the Chuck jaws here it's not going to be super ideal but it's the best I'm going to get so what I'm going to do is I'm going to probably need to do it in two stages I'll carve away over here till I get down to the right diameter and then bring bring it up to the shoulder and just sort of blend it together the center portion here is going to get grooved anyway so if there's a blend line that doesn't matter yeah we'll just we'll make do with this that turns out that this journal here is actually a little wide yet so I can I can peel away from this shoulder this way it's actually got to be 940,000 snot one inch one twenty so that buys me a bit of more space too anyway I'll just start carving away this journal here has to go from there whatever it is two inch one sixty seven or whatever it is has to come down to one inch 930,000 so let's see how this works okay I'll try that angle we'll see how much it vibrates on the compound [Music] [Music] well hello boy well that sucked I don't know how much hey they caught that hey well only point nine nine to another sixty thousands to go that kind of sucked that was decent camera [Music] [Music] man is a stuff ever stringy if I had to make a guess I if I had to make a bet I would say this is 41 40 [Music] [Music] note that I will never use a lathe on a file without a handle on it and then I am right-handed but I do file left-handed Lee on the lathe so everything on here is in relation to this front face so we should be able to do is use our fat sharpie marker tool a black marks on here and then we should be a little layout where the grooves go they're not that expensive I don't know it took me so long to get one I need to make a line like I say they're just they're very rough marks as far as where the where the groove has to be now these two lines here will indicate where the tops of the two walls of the V wind up I want to carve the groove in the center first and then cut the walls to suit now that groove in the center will be 325 thousands from this face and 625 from this space will be that that'll be the width of that groove it's about 300 thousands wide in the base of a beat pulley groove so I got set up here at the parting blade what I'm going to do is as I say I have to take it down to depth in the center Center depth is well the outer diameter here is two point six one inner diameter is one point five three that means I have to take 1.08 off you ever take one inch eighty so divided by 2 that's five hundred and forty thousands I'm just going to touch off here with the once I touch off then I'll set my my cross-slide dial and just go from there I'm not going to part straight in I'm going to cut a little bit and then work to the side and back and forth hopefully that will lessen the chance of this parting blade dying an early death parting on this thing is always a bit of a trick so let's see how this works I have cut pulleys on the lathe before again it's just a bit tricky to try to get a solid mount to be able to do use the parting bit so here's hoping this works I used I did the other ones in a different manner because I wasn't using such a short piece of material I guess it's what I get for trying to be cheap and use up small bits of stock [Music] so you can see the beginnings of the of the groove happening here what I'm going to do is I'm going to pause and I'll bring you back in once we're pretty much down to depth I'm sure you don't want to watch all this and because this is a farming operation we're gonna go nice and slow oh here goes what I'm doing is I'm going in steps a carve in a little bit and then move over and then what that does is that lessens the length of material being cut on the on the tool bits edge here so I can see I'll just I'm working to the right a little bit what's that that's going to do is that'll create a little step further in so now is a crank n-word it's only cutting on a part on part of the cutting edge there we go now starting to cut in more of it so that's increasing our required pressure so it back it off a little bit of oil right now I know that a lot of you are just going to be you know wondering to yourselves why I didn't do this in the same manner that mr. Pete did a couple of reasons well three actually this form tool I have from making a few other pulleys before because I've made B pulleys before granted I was doing it with stock that was sitting out here and easier to get at and whole nine yards so I mean it was it was a little different set up that way partly also just because I'm trying to use up some scrap I'm so close to Chuck that I'm kind of iffy about trying to get this thing set up angle wise as far as using the compound and I mean the and the other reason is I don't have a mandrel mr. Pete used a mandrel for his is that way he just take it and flip it over or leave the compound set and stuck out here I don't have a mandrel so yeah I'll just use it I just did it this way I've made pulleys this way before it takes a little bit longer but it does work so anyway I know some of you are going to be you know scratching your heads wondering why I did it chose to do it this way and that's why as far as you know as far as the witness marks here because I'm starting to lose my AGP marker yes I should have used the doc M blue it's a little more resilient what I did was just made a carve over to the line there so I know where I need to stop now I'm gonna do the same thing over here and then that I'm just gonna carry on finishing out the groove okay we're just about there just about the bottom of the groove there we are I think that's pretty much there after a bit more shaving because again it's I do only had to take a few more thousands off the off of either side and that now has about the same fit as it did in the factory pulley oh that well came with the motor even though it's not the original motor that came with the shaper 34° sides I can feel a bit of a sharp edge on these lips here but once I take those off it'll be golden so now I'll do the smaller diameter groove you've seen me do this one you don't need to see me to two of them once I'm done this one then we'll cut it off and move on to the next step so anyway this is the aluminum pulley that came with the motor a little bit of stick out there not a whole lot we have pretty much the same profile now on both of our grooves on this pulley so we're gonna call that done as far as forming the grooves what I need to do now is get this cut off or well actually what I'm gonna do is I'm gonna take the sharp edges out these corners will get it cut off and then we'll face it I'm not even gonna try parting this thing in this lathe right now I have been having enough great with the parting tool so what I'm gonna do is I'm gonna figure out some way of cutting this off in the bandsaw I'll do that off camera so the sketchiness isn't really you know broadcast and you know I don't want to be a bad example too much and then I'll bring you back in when we're ready to face the other side [Music] there we go yeah not spectacular but it'll work [Music] there we are there yes I cheated give a little better surface finish on the end all right hooray not too much dingy John the wood outside well from the jaws good there we go three steps remain broach the key way it's a 3/16 key way and then I need to drill and tap for a 5/16 set-screw now although the pulley is not completed at this point I think I'm gonna have to call it here otherwise the video is gonna get extremely long because there's a fair amount more work yet to do so yeah I'll have Part B up soon - it'll have the making of the broach bushing and that we need for this as well as the set screw and installation on the motor so otherwise I hope you found it interesting so far I know that I have ways that I do things that others may disagree with and that's fine but you know hopefully you found it interesting at least so otherwise thanks everybody for watching thanks for subscribing if you do and we'll see you next time for Part B [Music]

Channel: Everett's Workshop

Views: 3,474

Rating: 5 out of 5

Keywords: everett's workshop, hobby machining, alba 1a, alba shaper, metal shaper, making a pulley, custom pulley, turning a pulley, camera damage, b pulley, lathe form tool, pulley form tool, b sheave

Id: qDmWOqWLx_w

Length: 24min 34sec (1474 seconds)

Published: Sun Aug 04 2019