Machining A Replacement Pulley With A Keyway

Machining A Replacement Pulley With A Keyway, by Clickspring.
In this video, I machine a replacement pulley for my 1" Delta belt sander. This is a perfect mini lathe project, with some interesting turning between centers, as well as the formation of a keyway using the lathe as a manual shaper.
Be sure to use breathing protection whenever using heat to break a super glue bond.
You can download the dimensioned drawing for this particular pulley for free from the Clickspring website:
Metric: www.clickspringprojects.com/up...
Inch: www.clickspringprojects.com/up...
Thanks for watching. If you enjoyed the video please give a thumbs up, and leave me a comment.
If you would like to help support the creation of these video's, then head on over to the Clickspring Patreon page: / clickspring
You can also help me make these videos by purchasing via the following Amazon Affiliate links:
Cameras used in this video:
Panasonic GH5 - amzn.to/2rEzhh2
Panasonic X920 - amzn.to/2wzxxdT
Tools & Shop Products:
"Solidworks 2013 Bible": amzn.to/2FObS1D
Digital Calipers: amzn.to/2IkFh4O
Anytime Tools 5 Lathe Mill CENTER DRILL : amzn.to/2IThppO
Dormer A190202 Jobber Drill Set, 1.0 mm - 6.0 mm x 0.1 mm Size: amzn.to/2DR5fdb
Dormer A190203 Jobber Drill Set, 6.0 mm - 10.0 mm x 0.1 mm Size: amzn.to/2ITfeTa
YG1 NC Spotting Drill 8% Cobalt HSS 1/8 to 1/2" 120 Degree 5 Pc Set CNC Machine: amzn.to/2G7ylv6
Dykem 80300 Steel Blue Layout Fluid, Brush-in-Cap (4oz): amzn.to/2HGPaJJ
Generic Dial Indicator 0.001": amzn.to/2FOFTyF
Interapid Dial Test Indicator: amzn.to/2FPInwH
For more info on this build, as well as other tool making info and plans, visit www.clickspringprojects.com
Ask Me A Question:
www.clickspringprojects.com/co...
Language Credits:
Portuguese subtitles courtesy of Emanuel Mendes
Abbreviated Transcript:
00:50 The second is the v-groove for the belt. It's has a 30 degree included angle, and not very deep, so I'll form that with the lathe compound. And lastly, there's the set screw hole, which I'll do on the mill. If you'd like to know the dimensions, I've put a link to some free drawings in the description box below.
01:07 These are the materials I'll be using for the job. I've got this excellent little piece of aluminium that's a left over from another project, although it's a bit too short for chucking, so I'm going to turn it between centers to form the features. So that means I need an arbor, and I've have this nice length of silver steel for that.
01:40 The arbor needs centers on each end, so I set it to run true in a 4 jaw chuck, and then faced and center drilled the ends. Next I drilled and then reamed the slug of aluminium to match the outside diameter of the arbor.
02:35 The work is a nice close fit on the arbor, so a small amount of the glue is enough to hold it firmly in place for the rest of the job provided I don't let the heat from the cutting, build up too much. I formed a temporary center from some hex stock, and then set up the lathe for turning between centers.
03:46 Next I formed the basic profile of the part. I'd like a nice generous fillet in the corner for strength, so I've ground quite a large radius on the cutting tool. a lot of cutter contact when it's right in the corner, but a shallow depth of cut It means there's made the chatter quite manageable.
04:24 Then I set the compound over to 15 degrees to cut the flanks of the groove. I've ground this narrow, blunt nosed cutting tool to do the cutting. It can cut on both sides of the tool, which is going to be handy in this case, to get a matching surface at the bottom of the pulley groove.
05:43 The facing cuts didn't quite get to the arbor, so there's a small burr at each end of the hole to take care of. I used this hand held countersink to knock them off. So with the profile complete, it's time to sort out the keyway.
06:37 I started by feeding in 2 thousandths with each pass to begin with, but as the cut became more established, I had to reduce that to a half thou per cut, and make 3 passes at each depth. I found that any more than that put too much strain on the carriage wheel.
07:11 The cutting action is not unlike that of a
shaper; it makes similar looking chips. And it generates quite a clean cut. So with the keyway finished, the pulley is almost complete; It just needs a quick trip to the mill to drill and tap a hole for a set screw.
References:
MACHINE SHOP TIPS #151 Cutting a Keyway on the Lathe - a new ''abroach" tubalcain
• MACHINE SHOP TIPS #151...
Machining A Replacement Pulley With A Keyway, by Clickspring.

[@madnessbydesign1415]

"Sure, I could go buy a part to fix my tool... or I could make tools to make more parts to fix my tools, so I can make more tools...". I hope you never get tired of making these, because we will never get tired of watching them... :)

[@wyvernflight]

So far I've seen about half of your videos and have come to the conclusion that you are the Bob Ross of machining. No problems just happy little gears....

[@kevinbyrne4538]

Not only are you a skilled machinist, you're also a fine script writer, a wonderful cameraman, and a great editor. An economical presentation: hardly a word or second wasted. Beautiful work. Keep it up.

[@mikesmith5453]

Man, I can hear your heart is in this work. Keep it up.

[@kellerrobert80]

Your lighting and close-ups are best-in-class. No other machinist comes close.

[@tomsdreamshopworx]

The quality of your projects and the video work has no equal. The best on KZbin! Thank you for your time and energy.

[@Clickspring]

Terrific to have your support Tom :)

[@MacroMachines]

+Tom's Dreamshop Worx. Absolutely. And his 👍🏼/👎🏼 ratios are the best I've ever seen

[@salomonvallesreyes7366]

A pleasure to watch your video... You have the sense to film it short... And long enogh to share all the needed technics...Thanks a lot for sharing...!!

[@tobiasgertz7800]

Patience of a saint. Cutting that keyway must have been tedious. Thank you for all that you do.

[@crolodon8024]

I check this channel for new videos twice a day. I'm hungry for more. Please...

[@Clickspring]

Crolodon Going as hard as I can to get 'em out :)

[@MachinistOfPhotography]

Don't know if anyone mentioned this yet but I got a quicker way to get to the final depth of the key way. If you have a end mill the same size (or smaller) as the key way and long enough. You can cut to the depth of the key first with said end mill. Then come back with broaching tool and all thats left is the radius from the end mill and maybe some material on the side walls if an undersized end mill was used. Much less material for the broaching equals much quicker. You might of known or heard this already but thought id share some advice. From a entry level machinist here in Texas

[@Clickspring]

+Zac Tart Great suggestion Zac, I'll try that out next time! Thanks very much for sharing :)

[@HrushikeshNaik1650763n73]

that's a better method to make the keyway

[@HrushikeshNaik1650763n73]

that's a better method to make the keyway

[@hughpearson3191]

TICK for Zac :) yep...that's a good idea

[@randolphcatchot5421]

This guy would make a good teacher, well spoken and is quite the brain in this field no doubt...

[@624Dudley]

Hello Chris - revisiting this early video since it pertains to a project I have underway. It’s just as good years later! 👍

[@kaoshavoc]

How do you even get started with such a hobby ? I would love if you would make a video talking about how you started, and what your first projects were like. How your tool collection grew. Your videos are amazing. I love watching you make your own tools to make your own stuff.

[@MrOffizier]

Man, i would die for such a bright and well equipped workshop. When I get older I want to buy such nice gear and build such a workshop myself. I just love craftsmanship. Love your vids :)

[@Clickspring]

+MrOffizier Lots of light required for my tired peepers :) thanks for watching.

[@JonScottSmith]

Glad to see you created a Patreon. Pledged to help fund the stunning work you're doing here. The transcript in the video description is a really nice touch.

[@Clickspring]

Jon Scott Smith Thank you very much Jon, I really value your support.

[@jeffduring1]

That was fantastic. I don't have a mill at the moment and you answered how to cut a key way without one. Thanks.

[@Clickspring]

Cheers Jeff

[@digitalchaos84]

how could anyone downvote these videos seriously, every aspect of this channel is totally amazing work, not only the machine work but the camera work, editing, narration and everything else.

[@MattsAwesomeStuff]

If you ever wonder "I wonder if anyone notices when I put more time and effort into my production value?", the answer is yes, we do. All kinds of new techniques in this video. I hope it feels like fun, rather than work, to be getting increasingly more skilled at video-making as a side-effect of producing great content. Delightful and educational to watch. I aspire for my videos to be as well shot and edited as yours. Well done, as usual.

[@Clickspring]

MattsAwesomeStuff Thanks very much for letting me know that Matt, I appreciate it :)

[@northernsmith]

I just used your keyway cutting trick the other day. I used my boring bar and a 3/16" bit to cut a 6mm keyway. It worked very well! 😀

[@AbeDillon]

I love your editing skill. That "radio tuning" effect you do to overlay the plan is really slick.

[@Clickspring]

+Abe Dillon Cheers Abe, great to have you watching :)

[@jamesnicholson3313]

Mate I never get tired of watching your videos. Jim.

[@dp4racing]

Excellent video production quality! High resolution, great lighting, you speed it up at the right times to keep interest. Music is not louder than your voice, music not obnoxious. The quality of your projects is amazing. I could watch these all day!

[@Clickspring]

Terrific to hear that David!! Terrific to have you watching :)

[@dmorris125]

I worked as a model maker for a large manufacturer of power tools and kitchen appliances, and have retired as a product design engineer. I admire your skill as a machinist and film maker. I have learned a great deal from you. Please keep these coming. Thank You DM

[@Clickspring]

David Morris Thank you very much David, will do.

[@Ujeb08]

I'm glad to see that you did a video on how to use a lathe as a shaper for keyways. It also works great for making a blind keyway where a broach can't do the job. I've used this method a long time ago with great results. These days I use a wire EDM. But still can't make a blind keyway in the wire.

[@tylerpwm5782]

I would have never thought of cutting the keyway like that! Really love you videos and keep em coming! Thank you

[@sirtooby]

Tyler PWM I agree, never seen that. Must remember this 😀

[@tfre3927]

So satisfying to watch. So simple, yet so perfect.

[@thicknight1]

Amazing work Chris. Happy to support you. Who needs television when there's talent like this on KZbin? Can't wait for your lathe video.

[@nickarello5266]

you never fail to leave me we wanting a lathe and mill each video

[@Clickspring]

Terrific to hear that :)

[@jkack53]

I have only watched a few minutes of this video, but is TOP RATE and so clear.

[@joshuasamuels4802]

Your talent and improv skills speak volumes of the level of mastery and passion you have of your craft. Glad I subscribed!

[@anthonyctube]

After threatening to buy a used mini lathe for the last 5 years, I bought one last week. With a minuscule idea about how to use a lathe I jumped in at the deep end. Your videos are the equivalent of a lifesaver for me. You make everything seem so easy ( which I am sure comes with practice ) Thanks Chris.

[@Clickspring]

+Tony Camilleri Great to have you watching Tony :)

[@daveh777]

Very nice! Great video as far as production, and visual clarity of each of the steps! Kudos!

[@chrissd40]

Wow, I need to make a step pulley for my small mill and had no idea how to proceed. Your video gave me exactly what I need to start this job. And your quality is fantastic! Thanks!!

[@timhofstetter5654]

That's the first time I've ever seen a valid use of both a straight dog and a bent dog at the same time on the same work setup.

[@matthewphelps5136]

Need more CLICKSPRING video's. Not enough of them!

[@Clickspring]

+Matthew Phelps More on the way soon, thanks for watching Matthew :)

[@karlphilipp93]

Beautiful work! Love watching your videos, informative, yet relaxing at the same time!

[@BadazzGregg]

I'm absolutely mesmerized by this video. Industrial sewing machine motors commonly have a keyed shaft for a 3L fractional size V belt just like this pulley here.

[@Mike-rq1pt]

I like the close-up videography... Finally some person that knows how to film and edit

[@gusbisbal9803]

Best machining videos on the web, best explainer videos ever.

[@Clickspring]

***** Thank you very much Gus.

[@Just1GuyMetalworks]

Right on, Chris! I'm working on a project that will require an internal keyway and wasn't sure if that was a plausible way to do it. Thanks for the video!👍😁👍

[@Bluematchhead]

I get giddy every time I hear the X-ray sound and we get the internal view of the piece of stock you're machining! Fantastic videos!

[@ahmedbig34]

man you are a factory of your own .i can`t get enough of your videos. i`m subscribing .

[@Clickspring]

+Ahmed Utab Terrific Ahmed, very pleased to have your sub

[@Zerostar369]

While I'm fascinated by the process and love these videos I find them so soothing that I almost always fall asleep during!

[@mikewasowski1411]

Your videos are amazing and inspirational. So many good ideas. Makes me want to jump back on my little mini lathe which I haven’t used in soooo long. Thanks again for sharing such brilliant content 👍

[@MrNathanShow]

Thank you for this such high quality production. This is really feeding my machining interest and it is beautiful to watch you work.

[@Clickspring]

+Nate Guy Great to have you watching :)

[@aspenbanjo]

One of the finest pleasures in life is making parts for machines. Once again, you've created an excellent product and an excellent presentation. Thanks Chris!

[@Clickspring]

aspenbanjo Cheers mate!

[@adamv242]

Just discovered this channel a week or two ago... fascinating to watch someone this skilled.

[@wojtaswrr]

film pięknie, profesjonalnie wykonany, świetny montaż i efekty specjalne. jestem pod ogromnym wrażeniem.

[@Harrzack]

After seeing enough of my own 'metal-butchery it is quite a treat to see a part made cleanly. Beautiful - even if 'just' a pulley.

[@semperidem2577]

The only criticism I have is that you make things look so easy, that I think even I could do it. Lol. Great stuff!

[@joebonomono5078]

Im very tired and watching without volume, i thought i was watching a seamstress channel i occasionally watch, and i thought wow... this chic has really leveled up in her sewing...shes machining her own sewing bobbins now. I was hugely impressed. I need more sleep.

[@BillEgnatoff]

Just what I needed. Beautifully produced video that served also as a great refresher on design, layout, and basic lathe techniques. Also appreciated Zac Tart's alternative for making the keyway.

[@Clickspring]

+William Egnatoff Cheers William, thanks for watching :)

[@roymackeys]

Thanks for the video!!! Showed me just what I needed to know. Nice fast paced easy to watch!!! Short and right to the point. Look forward to seeing more.

[@Clickspring]

Cheers Roy, thanks for watching :)

[@goyslop4289]

only Chris gets excited when parts break lol, great video sir!

[@nassimback]

bdub z haha so do we :D

[@FuddButter]

Between watching both you and Ave, It makes me so want to buy a lathe and a mill etc.. I miss doing things like this, but I have only ever done small things, would love to learn a lot more! Thank heaps!

[@dannymaciejewski]

Hi, you would like oxtool and abom79 then too I would bet.

[@FuddButter]

+dannymaciejewski cheers man, I'll check them both out!

[@worldcrafter]

eye opening howto for cutting a keyway. excellent work!

[@cogentdynamics]

Your craftsmanship and videos are both beautiful! Thanks

[@joeestes8114]

Thats the first time I've seen a skyway made that way! Awesome video!

[@453421abcdefg12345]

That is a piece of art! Nice to see you using a centre drill !

[@mr.heineken5770]

Now that's a HEAVY DUTY Pulley! Great work!

[@MrChrisKnowlton]

Fun and educational to watch and I love the phantom "part-in-the-blank".

[@motorv8N]

Just stumbled across your channel during a search for parts for the old drum and cable style boat steering systems. Top notch production quality and fascinating projects. Subscribed!

[@michaelbritton9778]

Lovely bit of workmanship love watching engineering projects I was a turner for a few years

[@daveys]

Quality outcome as always! As you say, a replacement part can be bought cheaply, but it’s great practice for the replacement parts that can’t be bought at all!

[@M3iscool]

Your accent is magical. I'm not being facetious at all, your voice is just-- beautiful.

[@bzakie2]

Cat From The Future It's Australian.

[@hillbillyvilly7522]

I agree! It's like listening to a professionally made video. Well done

[@markfrench8892]

Learn something new with every video you post. Thanks!

[@lornobe5324]

Your workshop is impossibly clean and perfect. I'm severely envious. Great videos.

[@Clickspring]

+Lorn Obe Cheers Lorn, thanks for watching.

[@winsomehall6686]

Hi Chris, There is so much CNC stuff on the web watching you work is like a breath of fresh air. Amazing what you achieve considering the fishing is so good up there. Quite envious of the temperature at the moment also. Cheers Andrew

[@Clickspring]

Winsome Hall Ha! This time of year is what makes up for the wet season! Thanks for watching mate.

[@diego_garcia_cacho]

awesome how you made the keyway, I love simple solutions that work beautifully!

[@Clickspring]

+diego Garcia Cheers Diego, thanks for watching

[@jeanpafy]

These videos are so good. Please continue.

[@Clickspring]

***** Thanks for watching Nicolas, will do.

[@walsayer]

I liked the super-embossing of the 3d design over the piece at 3:33. Good Job.

[@Clickspring]

Waheed Alsayer Thanks for watching Waheed.

[@topallielton]

Set a side the machining skills which are out of this world, but man the camera work. Wow. Great video.

[@Clickspring]

Elton Topalli Thanks very much Elton, I appreciate it.

[@johnkoutros9325]

I just have to say I really enjoy your videos , your attention to detail is superb

[@johnmartin6178]

A very enjoyable video, takes me back to my apprenticeship days. I love making things and always wanted an workshop at home but never managed it.

[@josepharmstrong9882]

man youre blogs are awsome you are teaching me so much please keep on posting them Thank you.

[@Clickspring]

Will do Joseph, thanks for watching

[@alcoxy]

One of the best things about Clickspring is that you use your tools to make or fix others

[@Clickspring]

+Almo Cox Appreciate your support Almo, cheers mate :)

[@landadvice1]

Beautifully filmed as well, timeless.

[@ScottTurnerformeindustrious]

Great work Chris, on all accounts!!

[@1959Berre]

Watching these video's is soothing my soul.

[@Only_Cans_101]

What a beauty, cant beat making it yourself, over buying it, well done!!

[@matter9]

Beautiful work and production. The Solidworks overlay was a neat touch

[@Clickspring]

Spencer Clayton Thanks for watching Spencer.

[@Patroand]

Seems that you have as much pleasure to make the videos as we have to watch them. Warm regards.

[@calomancer]

These videos are so soothing. I love watching these to relax and learn something new. :)

[@Clickspring]

Jacob Janson Thanks very much for watching Jacob.

[@fredriksuokas7697]

Love your videos. Very good explanations step by step, an cool stuff you make too. Haven't done this kind of builds since my youth in school in metal works. Did all sorts of things similar to this, mut not near the quality and skill you put in to it. Thanks to you I'm now planning to continue my hobby where I left of 13 years ago, and maybe, maybe some day I can make a living doing the things I love the most, creating pieces of pure art, just like you. Keep up the good work :)

[@carmelbuttigieg2177]

Followed every second of it. Fantastic.

[@IvanStepaniuk]

Impressive quality both in your work and the production of these videos. Keep them comming Chris!

[@Clickspring]

Iván Stepaniuk Thanks very much Iván, will do.

[@sephreed1938]

The feeling I get when watching these videos is akin to that of a lava lamp, or really sweet light show. But much less flashy. Thank you.

[@Clickspring]

+Seph Reed Thanks very much Seph, great to know you're watching :)

[@emccox3]

You videos are fun to watch. I learn new techniques and facts about machining which interests me as a young maker. Keep it up :)

[@LanceTheBlueKnight]

That keyway trick was black magic to me; I've never seen anyone do that before.

[@hazelhazelton1346]

You always sound so cheerful and happy. I like that. :)

[@pierresgarage2687]

Excellent work on the machining and the video part... Agreed that this pulley will outperform just about every one available commercially...

[@Clickspring]

pierre beaudry Thanks for watching Pierre.

[@liquidtool]

Oh man. This is my new favorite channel.

[@Clickspring]

Joe Doesntcareaboutthis Excellent, thanks for tuning in.

[@TehRealCanadarocker]

I had no idea you could cut a keyway like that, very creative and making due with what you have

[@Clickspring]

+TehRealCanadarocker Cheers mate, thanks for watching :)

[@EZ_shop]

The quality of your videos (and the parts you make) is very impressive!

[@Clickspring]

+Crivo152 Thanks very much for watching :)

[@EZ_shop]

+Clickspring I'm trying to improve my videos and I'd love to see the kind of setup you use to shoot your videos, especially how you take those 360° panning shots like at the 8:00 minute mark.

[@terryhalsteadgamer]

Amazing videos and commentary as always! Loved the part where you Xray in the design. Cool trick.

[@Clickspring]

terry halstead Ha ha! terrific Terry, thanks for watching :)

[@TangentJim]

Great Video -- It has a beginning--a middle and and end . Well planned -- the viewer now has an idea which way the wind blows ----two thumbs up. No wasted time on BlA Bla Bla -- the sequence of events are chronological -- great narration -- nice details

[@damonfendrick1]

The quality of your videos is great! I appreciate your work!

[@Clickspring]

+fendrickd Thanks very much for watching :)

[@Garageworkshop]

I get so excited every time I see a new video from you. Great work as always.

[@Clickspring]

Garage workshop Thanks very much for your continued support :)

[@Mikeanddrea]

So memorizing to watch.

[@r1273m]

Very interesting and superbly made video. I did a similar project myself but the arbour had a threaded spigot with a nut and washer to hold the blank in place. I have never seen superglue used in a situation such as this. I did mine 50+ years ago so superglue wasn't around then!