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46 Bean Cutler-2


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#1 jdcrawler OFFLINE  

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Posted February 22, 2012 - 04:44 PM

This tractor didn't have the engine or drive pulley when I got it.
I advertised on about a dozen different internet forums and Yahoo groups for a pulley or information on the pulley so I could re-manufacture one.

I never did find a pulley but one guy contacted me with the information I needed to make a pulley.
This is what the original drive pulley looks like.

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The brake pad material for the sides of the pulley was purchased from Mc-Master Carr.
The two pads are measured out and the center holes are drilled thru so I know what diameter to make the support bosses on the pulley.

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There was a piece of 4-1/2 inch diameter aluminum in my metal storage.
This is chucked up in the lathe.

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The first side was faced off and the outside diameter was trued up.
Then I turned the piece around and turned the rest of the outside diameter.
The support boss was then machined on the face.
The center bore was also put in at this time.

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checking the fit of the pad on the pulley.

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The pulley was turned around again and the support boss was machined on that side.
With that operation done on the pulley, I drilled the holes in the pads for the mounting screws.

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These hole are then counter-bored.

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The pads will be fastened to the sides of the pulley with these 1/4 inch flat head screws that fit into the counter-bores.

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Mounting holes are then drilled into both sides of the pulley.

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I use the drill press to start the taps so the threads will be square to the face of the pulley.

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The threads are finished tapped by hand.
A standard tap pushes the thread chip down into the hole so I use a spiral tap on blind holes so the thread chip is pushed out of the hole instead.

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With the holes all threaded, the pads are mounted on both sides and the pulley is chucked back up in the lathe.
The outside diameter is turned down to size.

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then the 30 degree angle is cut on the sides of both pads.

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the outside diameter is then turned with a 5 degree taper cut on both sides to form a raised area in the center of the pulley.
This taper cause the flat belt to constantly ride up on the center of the pulley.

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Now it is time to put the keyway into the bore.
This is a keyway broach kit.
It has a broach tool holder that fits into the bore.
The broach is then set in the slot and pushed down thru the bore on a press.
Once the broach has been pressed thru one time, a shim is placed behind the broach tool in the holder and the broach is pressed down thru again.
This process is repeated until the keyway is cut deep enough into the bore.

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Here's the broach being pressed down thru the bore.

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You can see how each tooth on the broach shaves off a thin bit of metal and rolls it into a ball as the tool is pressed down thru the bore.

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Here's the finished keyway in the bore.
All that is left to do is drill and thread two holes down thru the outside diameter of the pulley.
One hole will be for a set screw to tighten on top of the kewyay and the other for a set screw to tighted on the side of the crank shaft at 90 degrees to the keyway.

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#2 wvbuzzmaster OFFLINE  

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Posted February 22, 2012 - 05:23 PM

Wow Ray, awesome work on that pulley. Keep up the great progress.
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#3 caseguy OFFLINE  

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Posted February 22, 2012 - 05:32 PM

Thanks for the lesson Ray! I always wondered how keyways were cut. I even knew that the tool was called a broach, but I'd never seen one! Excellent work as always!
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#4 Ryan313 OFFLINE  

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Posted February 22, 2012 - 08:04 PM

Amazing job remaking that pulley! Looks great!
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#5 achomesteader OFFLINE  

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Posted February 23, 2012 - 06:01 AM

Interesting build Ray. :good_job:
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#6 KennyP ONLINE  

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Posted February 23, 2012 - 06:19 AM

Nice pulley. And thanks for the lesson on how to build it, Like the 'crown' to keep the belt on, pretty neat.
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#7 mjodrey OFFLINE  

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Posted February 23, 2012 - 06:29 AM

Ray,your fabbing skills are still amazing me.
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#8 trowel OFFLINE  

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Posted February 23, 2012 - 08:55 AM

Impressive, you do Great work.
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#9 jdcrawler OFFLINE  

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Posted February 23, 2012 - 12:21 PM

The holes are drilled and tapped for the set screws and the pulley is fit onto the engine.

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#10 Michiganmobileman OFFLINE  

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Posted February 23, 2012 - 09:16 PM

Wow that was really neat to follow, YOU GOT ALL THE TOOLS!! I thought by looking at the first picture that maybe there was no belt. How does that beveled brake pad connection function? A curious machine for sure. Thanks for sharing.
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#11 jdcrawler OFFLINE  

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Posted February 23, 2012 - 10:05 PM

I thought by looking at the first picture that maybe there was no belt. How does that beveled brake pad connection function? A curious machine for sure. Thanks for sharing.

The engine moves up and down and is controlled by a cable.
The engine is dropped down on the drive belt to run the tractor forward.
It is pulled up so the brake pad surface on the engine pulley rides up against the inside edge surface of the transmission pulley to run the tractor in reverse.
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#12 KennyP ONLINE  

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Posted February 24, 2012 - 04:45 AM

Now that's a neat way to get a 'transmission'. Glad you found someone with pics to help you make this 'pulley'. Awesome work!
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