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Shaw Du-All -8


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#1 jdcrawler OFFLINE  

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Posted September 25, 2011 - 12:01 PM

I have a couple of belt guards off garden tractors that used a starter/generator but they are too short for this setup so I'm going to have to build one.
Start with cutting a 2 inch wide strip of sheet metal.

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Then I bent a 1/2 inch lip along one side.

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Using the stretcher/shrinker to form the smaller end.

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Checking the fit.

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Here is the finished outside frame ready to be welded together.

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The ends of the frame are welded together and I added a flat piece of metal to the smaller end.
I made up an "L" shaped bracket that is fastened to the front of the flywheel cover.
The top of the belt guard is bolted to this bracket.

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There is a round plate that fits on the flywheel cover.
I fastened a piece of 1/4 inch steel to the inside of the flywheel cover behind two of the mounting holes at opposite ends for this round plate.
Then I drilled and tapped the two pieces of steel.
I made up two more "L" brackets that are welded to the inside of the belt guard and are bolted to the flywheel cover.
These three mounts make the belt guard nice and solid.

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I found this small sink rack at Walmart and thought it would make a nice grille for the opening.

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The grille is sandblasted and trimmed to size.

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The grille is welded to the inside of the belt guard.

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Here's how it looks with the rope pulley back on.
I also got the gas tank straps fastened on.

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#2 wvbuzzmaster OFFLINE  

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Posted September 25, 2011 - 01:14 PM

That is a pretty nice looking belt guard. That sink rack was just the ticket too.
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#3 jdcrawler OFFLINE  

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Posted September 25, 2011 - 01:48 PM

Looking at this today and got to thinking ... this engine has electric start so it really doesn't need that rope pulley.
They had a lot of small machinery back in the 20's, 30's & 40's that was run by engines that used a flat belt to power those machines.
Scrounging thru my parts, I found a 4 inch diameter, cast iron flat belt pulley.
I think I'm going to take off the rope pulley and replace it with the flat belt pulley.

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#4 MH81 ONLINE  

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Posted September 25, 2011 - 01:58 PM

Ray, fantastic work, and I love the idea of the belt pulley. If it's to be more that aesthetic, you may want to setscrew that very well. With the threads, the pulley is tightening while running, if the engine runs out of gas or something stalls it with the piece of machinery running with inertia, it could spin that cast piece right off the shaft. That's why belt pullies were splined on almost everything.
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#5 jdcrawler OFFLINE  

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Posted September 25, 2011 - 02:08 PM

Actually this engine has standard right hand threads on the flywheel shaft so it wants to un-screw when it is running.
I'll make a shaft out of steel for the pulley to mount on and this shaft will tighten onto the threaded shaft with a big lock washer.
This shaft will also have a set screw in it like you mentioned and the set screw will seat into a hole drilled into the threaded shaft.
I figured that between the lock washer and the set screw, that it would stay on tight.

Edited by jdcrawler, September 25, 2011 - 02:26 PM.


#6 KennyP OFFLINE  

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Posted September 25, 2011 - 03:31 PM

More great metal work going on here. I like your metal former, that is a cool tool to have. Looking awesome as always.
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#7 mikebramel OFFLINE  

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Posted September 25, 2011 - 03:48 PM

Very nice. Craftsmanship
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#8 Gibby OFFLINE  

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Posted September 25, 2011 - 07:19 PM

I'm gonna go out on a limb here and guess that when you didn't have an existing belt guard, you weren't all that upset. "Oh well, I guess I'll have to play with my awesomely cool metal shaping tools again!"
Is it even necessary for me to say how sweet this build is looking? As always, we're all watching and drooling over your metal working skills!!!
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#9 olcowhand ONLINE  

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Posted September 25, 2011 - 07:56 PM

I'm gonna go out on a limb here and guess that when you didn't have an existing belt guard, you weren't all that upset. "Oh well, I guess I'll have to play with my awesomely cool metal shaping tools again!"
Is it even necessary for me to say how sweet this build is looking? As always, we're all watching and drooling over your metal working skills!!!


:ditto::ditto::ditto:

I would LOVE to have some...no, ALL of those metal working tools! I'd love also to have the time to use them, but then again, if I had them I'd sure make time to play!
But then you also need to have the skills to use the tooling, and that comes over time, which is evident you've been working metal for quite some time, going by your skill level! :thumbs:
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#10 trowel OFFLINE  

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Posted September 25, 2011 - 08:24 PM

That is a nice clean looking belt guard, better then factory and the wire cover was a nice touch, i have to confess, im a little jealous, looking great,
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#11 tinner OFFLINE  

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Posted September 25, 2011 - 08:25 PM

Ray, I've probably laid out and built somewhere between 400 and 500 belt guards over the years from small ones like you built to some that took two men to carry and I'm here to tell you that you did a great job on that belt guard. I'm loving your build.
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#12 jdcrawler OFFLINE  

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Posted September 26, 2011 - 03:42 PM

The end of the crankshaft that the rope pulley was mounted on has a 7/8-14 righthand thread.

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The bore in the flat belt pulley is 1-5/16 inch diameter.
I took a piece of 1-1/2 inch steel and turned one end down to fit the pulley.
On the other end, I drilled a hole and threaded it.

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The pulley end of the shaft has a 3/8 drilled hole for the set screw to set in.
I used this hole to tighten the shaft onto the crankshaft.

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Once the shaft was tight, I then drilled another hole thru the shaft and countersunk it into the threaded shaft.
This will take a 3/8 set screw to lock the new shaft onto the threads.

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The new pulley shaft is mounted on the engine.
The set screw for the shaft is opposite the hole for the set screw in the pulley.

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The flat belt pulley is then mounted on the engine.

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Here you can see how far the pulley sits out from the engine.

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#13 Deck_Drive OFFLINE  

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Posted September 26, 2011 - 04:40 PM

is there enough room in that pully guard so you can loosen the belt or tighten it?
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#14 mjodrey OFFLINE  

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Posted September 26, 2011 - 04:41 PM

I am just speechless watching your amazing fabrication skills go to work.Simply amazing Ray.
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#15 jdcrawler OFFLINE  

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Posted September 26, 2011 - 05:29 PM

is there enough room in that pully guard so you can loosen the belt or tighten it?

Yes .. the guard has about 3/4 inch clearance around the starter/generator pulley to allow for future adjustment.




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