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A very big
02GF74 - 27/4/09 at 07:38 AM

THANK YOU to MR Coozer.

For making this:

[Edited on 27/4/09 by 02GF74] Rescued attachment DSC04593.JPG
Rescued attachment DSC04593.JPG

02GF74 - 27/4/09 at 07:40 AM

so I, with a little bit of fettling, can do this:

just need to figure out how I can make use of the keyway to lock the bolt in place.

I have spun the puuely and it runs perfectly true so TOP JOB Mr C. (I think I would have really truggled to make this). Rescued attachment DSC04594.JPG
Rescued attachment DSC04594.JPG

owelly - 27/4/09 at 07:50 AM

Make a tab washer with an internal tab to locate in the keyway and an external tab to bend up the side of the bolt.

g.gilo - 27/4/09 at 08:38 AM

and it will all unscrew together?

MikeRJ - 27/4/09 at 08:50 AM

quote:
Originally posted by 02GF74
just need to figure out how I can make use of the keyway to lock the bolt in place.


You can't. Do the sleeve nut up as tight as you dare (IIRC it only has a 1mm wall, so it will probably be easy to shear), and use loctite if you are worried about it.

coozer - 27/4/09 at 11:14 AM

Thanks, I was wondering if it was any good.

I would suggest using a threadlock and nipping it up.

Was easy to make as I had the shaft with the thread and big hex nut anyway.

Cheers,
Steve

fazerruss - 27/4/09 at 12:42 PM

i may be wrong here but i can see a problem with that design. it apears that the pulley does not lock on to the nut ( the shaft on the nut needs a key way milling into it or the pulley will slip when charging a low battery) but then if you have a key and key way make sure the direction of rotation will keep the nut/pulley tight or as soon as you start the engine it will unsrew itself!

coozer - 27/4/09 at 01:27 PM

quote:
Originally posted by fazerruss
i may be wrong here but i can see a problem with that design. it apears that the pulley does not lock on to the nut ( the shaft on the nut needs a key way milling into it or the pulley will slip when charging a low battery) but then if you have a key and key way make sure the direction of rotation will keep the nut/pulley tight or as soon as you start the engine it will unsrew itself!


My Brise unit has a plain shaft with a little threaded bit for a nut, standard zetec pulley fits straight on no problem. Don't see a problem as there is no effort required to turn the alternator, it spins freely.

fazerruss - 27/4/09 at 02:19 PM

quote:
Originally posted by coozer
quote:
Originally posted by fazerruss
i may be wrong here but i can see a problem with that design. it apears that the pulley does not lock on to the nut ( the shaft on the nut needs a key way milling into it or the pulley will slip when charging a low battery) but then if you have a key and key way make sure the direction of rotation will keep the nut/pulley tight or as soon as you start the engine it will unsrew itself!


My Brise unit has a plain shaft with a little threaded bit for a nut, standard zetec pulley fits straight on no problem. Don't see a problem as there is no effort required to turn the alternator, it spins freely.



an alternator only spins freely when not connected/charging. that's why the fan belt slips and squeels on a cold morning when there has been a bigger drain on the battery to start the engine.

coozer - 27/4/09 at 02:22 PM

Point was its exactly the same as the zetec alternator. Good enough for Ford, good enough for me.

02GF74 - 27/4/09 at 02:34 PM

going back a few post - keying cannot work as the keyway from the pulley needs to key onto the saft but the bolt is in the way.


crossflow spins clockwise so nut will tend to be done up - yep I had considered that.

have to admint being old skool with truyst in split pins, key ways, castellet nuts, locktabs rather than these new fangled glues and sealant.

my concern is not so much as to losing the pulley, ok, that is buyablefrom burton power albeit £££ but the bolt itself, don't really want to trouble Mr C again.

fazerruss - 27/4/09 at 05:17 PM

quote:
Originally posted by 02GF74
going back a few post - keying cannot work as the keyway from the pulley needs to key onto the saft but the bolt is in the way.


crossflow spins clockwise so nut will tend to be done up - yep I had considered that.

have to admint being old skool with truyst in split pins, key ways, castellet nuts, locktabs rather than these new fangled glues and sealant.

my concern is not so much as to losing the pulley, ok, that is buyablefrom burton power albeit £££ but the bolt itself, don't really want to trouble Mr C again.


my idea was to cut a key in the bolt shaft, then fit the bolt to the pulley with key then screw the lot on to the alternator and as you say the ratation is correct it should keep nice and tight.
Im definately with you on the old school ways, must have caught it from me dad. Whenever he made somat it wer built to out last the human race

MikeRJ - 27/4/09 at 06:17 PM

quote:
Originally posted by fazerruss
my idea was to cut a key in the bolt shaft,


Walls aren't thick enough to cut a key slot into the sleeve nut unfortunately.

fazerruss - 28/4/09 at 06:53 AM

quote:
Originally posted by MikeRJ
quote:
Originally posted by fazerruss
my idea was to cut a key in the bolt shaft,


Walls aren't thick enough to cut a key slot into the sleeve nut unfortunately.


how about drilling a hole straight down through the pulley between the teeth through one side of the nut shaft then tap a thread through the lot. Then fit a grub screw which will be long enough to span the pulley and nut locking them together. If youre carefull you could at the same time dimple drill the alternator shaft so it will lock to that aswell.

flak monkey - 28/4/09 at 06:58 AM

How about just doing it up with some loctite on both the thread and the plain bolt OD, problem solved. Ideally use retaining adhesive rathe rthan thread lock. The only way that would ever come undone is heading it to 240deg+ with a blow lamp.

As an aside my alternator pulley is plain in the bore and has never slipped even when only gently nipped up with the nut.

David