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Pulleys, pulleys, pulleys!
By zmoz, Section Homebrewed Electricity Posted on Fri Dec 24, 2004 at 01:26:32 AM MST
Where can I buy them?!

So, I'm finally getting around to buying the pulley(s) for the welder/generator I've been asking a couple questions about lately. I want about a 3:1 ratio, and the alternator pulley is close to 2.6". That means I need an ~8" pulley for the engine. The only place I have found that sells them is Grainger, and the bastards won't sell anything to me.
Where the heck can I find an 8" pulley?
The closest I have been able to find is this:
http://www.surpluscenter.com/ item.asp?UID=2004122319091705&item=1-AM64X3/4&catname=powerTran s
But I'm not quite sure how I would attach that to the engine shaft. The other pulleys I have been looking at have a set screw to keep them in place. This just uses a key. If I put that on the engine shaft with just a key, wouldn't come flying off and kill someone?

Pulleys, pulleys, pulleys! | 16 comments (16 topical)

Re: Pulleys, pulleys, pulleys! (3.00 / 0) (#1)
by mlz on Thu Dec 23, 2004 at 06:33:18 PM MST

Go to a welding shop, or some bearing shops, and ask for a weld-a-hub. These are great. Another good spot is a farm supply. Get the perfect diameter on the pully, and you can select what size shaft.

Re: Pulleys, pulleys, pulleys! (3.00 / 0) (#2)
by monte350c on Thu Dec 23, 2004 at 06:41:35 PM MST

Yup - as Mike said Tractor Supply Co has a good selection of pulleys. Well at least in the store near here they do!

They stock a neat range of pulleys, where the pulley and hub are sold as two seperate pieces. The pulleys are cast iron and have a tapered hole in the centre. The hubs have the shaft size you need with a keyway on the inside, and a taper on the outside.

The hub goes into the pulley and the taper squeezes the whole thing onto the motor shaft - much tighter and more secure than a set screw.

I just got a 6" pulley and 7 / 8 ths hub for less than $15 there. Plus if you find the pulley is not the ideal diameter you can just get another pulley and use it on the same hub.

If you need a pic of this let me know and I'll take one and post it here.

I am also working on a gas powered alternator project. If it works out I'll post the details (looking for 110 volts AC output at a high frequency for lights/heat as a emergency backup)

Ted.

Re: Pulleys, pulleys, pulleys! (3.00 / 0) (#3)
by zmoz on Thu Dec 23, 2004 at 06:51:06 PM MST

Actually, I'm hoping to find some online. I live in a small town and there are no bearing, welding, or motor shops within a reasonable distance. There is only one farm store that I know of around here, and the biggest pulley they have is 5". (no "tractor supply co")

Re: Pulleys, pulleys, pulleys! (3.00 / 0) (#4)
by monte350c on Thu Dec 23, 2004 at 06:57:47 PM MST

Hi zmoz,

Try this link - I am not sure if they go as large as 8"

http://www.mytscstore.com/detail.asp?pcID=2&paID=1017&sonID=432&productID=104

you can enter in your zip code and see if there's one nearby. I am not sure if they sell online or not.

The pulleys are the best idea I have seen yet - very well made and secure on the shaft. If you want a photo let me know...

Ted.

[ Parent ]

Re: Pulleys, pulleys, pulleys! (3.00 / 0) (#5)
by zmoz on Thu Dec 23, 2004 at 07:15:25 PM MST

Closest one is about 1,000 miles away. :-)

[ Parent ]

Before you give up locally ... (3.00 / 0) (#17)
by Ungrounded Lightning Rod on Mon Dec 27, 2004 at 01:03:48 AM MST

Before you give up locally, check your oridinayr hardware stores.

Nere here, ACE Hardware has an assortment of pulleys available at very resonable prices. Also v-belts in many lengths to go with 'em.

[ Parent ]

Re: Pulleys, pulleys, pulleys! (3.00 / 0) (#6)
by bob g on Thu Dec 23, 2004 at 07:25:15 PM MST

the pulley you referenced from surplus center if it is the right shaft size for your application will work fine,

rarely will you find a keyed pulley that has no set screw, and if theirs does not, then there certainly will be a boss to drill and tap to install one.

i have never seen a browing pulley that doesn't have the boss, and rarely see one without a set screw, that one likely does on the other side of the boss, out of the picture.

here is another option, but in a B belt, which will work with a narrower belt, it will just ride lower in the groove

http://surpluscenter.com/item.asp?UID=2004122320184109&item=1-2177&catname=powerTrans

good luck
bob g

Re: Pulleys, pulleys, pulleys! (3.00 / 0) (#7)
by zmoz on Thu Dec 23, 2004 at 07:43:53 PM MST

If I go with that 5.625" pulley from surplus center, I'll end up with about a 2:1 ratio. I was hoping to be able to get full output from the alternator at 2000RPMs engine speed. Will my 100 amp alternator be able to put out it's full output at 4000 RPMs rotor speed?
(engine will be putting out about 6hp @ 2000RPMs)

Re: Pulleys, pulleys, pulleys! (3.00 / 0) (#8)
by monte350c on Thu Dec 23, 2004 at 08:01:38 PM MST

Hi zmoz,

I can't remember what type of alternator you're using, but here's a link to the AC Delco tech page on alternators: http://www.acdelcotechconnect.com/html/tas_alt_cs144.jsp

You can click the 'performance curve' link to see alternator output vs. rpm.

Since the digital cam is sitting here anyway I took a few pics of the pulley type I was talking about:

This pic you can see the hub sitting on the pulley. The hub is split like a collet, it is tapered and gets squeezed in a taper in the pulley.

The hub gets held into the pulley by 2 bolts:

And from the other side, when the bolts are tight the hub sticks out a small (a couple of thou) There are some threaded holes in the hub for taking the assembly off the shaft.

If you really get stuck I could give you a hand in getting them from the local store and shipping them to you...

Ted.

[ Parent ]

Re: Pulleys, pulleys, pulleys! (3.00 / 0) (#9)
by zmoz on Thu Dec 23, 2004 at 08:23:49 PM MST

Thanks for the link...that's what I've been googling for for a while. (wow, that sounds dirty :-) Looks like I won't get quite full output at 4000 RPMs, but close. I guess I'll just use the 5.625" pulley, 2500 RPMs vs 2000 shouldn't make that much difference in engine life.

Now, would it be better (or possible?) to use a "B" belt in the original alternator pulley, or an automotive belt in the "B" belt pulley?

[ Parent ]

Re: Pulleys, pulleys, pulleys! (3.00 / 0) (#16)
by monte350c on Fri Dec 24, 2004 at 04:15:14 PM MST

Hi zmoz,

I'm also trying to figure the best belt and pulley combo. It doesn't help that the pulley that goes on the motor has a fairly wide groove, where the one on the alternator is narrow - only half inch at the top.

I spend way to much time on Google, here's another link that might help make the belt decision: http://www.gizmology.net/pulleysbelts.htm

Looks like a compromise coming - unless I can get a pulley bore machined out for the alternator...

Ted.

[ Parent ]

Re: Pulleys, pulleys, pulleys! (3.00 / 0) (#10)
by Norm on Thu Dec 23, 2004 at 08:55:03 PM MST

What kind of engine are you putting this on? The pulley on the radiator fan on older cars is about that size just weld it onto a smaller pulley that fits your engine? (like someone already posted about a week or so ago? Hiker...I think?}
( :>) Norm
( :>) Norm

Re: Pulleys, pulleys, pulleys! (3.00 / 0) (#12)
by kell on Thu Dec 23, 2004 at 10:32:24 PM MST

You can weld with car batteries. Use heavy cable and hook them up for 24 or 36 volts.

Re: Pulleys, pulleys, pulleys! (3.00 / 0) (#13)
by Junkie on Fri Dec 24, 2004 at 01:48:20 AM MST

Cast one :)

http://backyardmetalcasting.com/castingpulleys1.html

Junkie
[ Parent ]

Re: Pulleys, pulleys, pulleys! (3.00 / 0) (#15)
by Norm on Fri Dec 24, 2004 at 06:27:24 AM MST

Yes I've got a 110 volt welder that don't hold a candle to a couple of good old junk batteries when it comes to really welding DC welding seems to be a lot smoother and easier to strike an arc and it's almost a surprise to see how much welding you can do on small welding projects like this...welding about 4 - half/inch places should only take about 20 seconds actual welding time.
Have Fun!
Merry Christmas!
Norm.
( :>) Norm
[ Parent ]

Re: Pulleys, pulleys, pulleys! (3.00 / 0) (#14)
by John II on Fri Dec 24, 2004 at 03:26:32 AM MST

Hi zmoz:

http://www.cookssaw.com

They have quite a few pulleys mail order at fairly reasonable prices.

Approximately here do you live ? I love out of the way places.

John II

Email: jjones(at)inter-linc.net

Pulleys, pulleys, pulleys! | 16 comments (16 topical)

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