Making Pulley Wheels from Plastic - Router Forums
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post #1 of 9 (permalink) Old 08-31-2016, 08:12 PM Thread Starter
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Default Making Pulley Wheels from Plastic

I have picked up a router crafter and need to make a replacement plastic 2 1/4" pulley...I saw a link where a guy took a hole saw and cut 3 plastic disks.One was a little smaller than the other 2. He used a drill bit with a 1/4" bit.He sandwiched the small disk between the 2 larger ones and pop riveted the 3 together.I need to know where I can find some 1/8 or so plastic and what is the best kind or right type of plastic?
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post #2 of 9 (permalink) Old 08-31-2016, 08:18 PM
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Any place that replaces windshields sells plexiglass and lexan . I like lexan as its not so brittle .
It comes in differant thicknesses ( I have 24mm ) so in theory couldn't you just route a groove into the inside of the outside perimeter .
To start , I cut circles out of the lexan using a perfect circle jig and a 1/4" straight bit

Just a heads up , but brace yourself when you see the price for what you would consider a scrap
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post #3 of 9 (permalink) Old 08-31-2016, 08:47 PM
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Would use phenolic laminate (canvass or jeans). AC and PC, and other thermo-plastics, will change shape and melt under load.
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post #4 of 9 (permalink) Old 09-01-2016, 09:55 AM
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I would use nylon it's available in a wide variety of thickness and small sheets. You could order the thickness you need and cut a grove in it under $20 for a 10"X 10" sheet. It even comes as a rod 2 1/2" dia, but very expensive ~ $75/ ft.
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post #5 of 9 (permalink) Old 09-01-2016, 10:05 AM
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See if you can find a small piece of UHMW plastic. The stuff turns easily on a lathe and is bulletproof.

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post #6 of 9 (permalink) Old 09-01-2016, 10:18 AM
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Just a suggestion,
considering the usage involved, I would fire up the old wood lathe and make one out of maple.
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post #7 of 9 (permalink) Old 09-01-2016, 04:55 PM
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Nylon rope pulley might work...like for clotheslines...

Did a google for 2 1/4 plastic pulley and got all sorts of stuff...

The bore might not be right but that might be easier to deal with than making a pulley...
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post #8 of 9 (permalink) Old 09-01-2016, 06:27 PM
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Lightbulb Make your own pulley wheel

Mike,

Take a look at this, it might give you some ideas:-


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post #9 of 9 (permalink) Old 09-01-2016, 08:44 PM Thread Starter
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Some interesting ideas..Thanks everybody!!!!
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