Simple solutions are always the best answer - Router Forums
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post #1 of 17 (permalink) Old 10-28-2016, 09:09 PM Thread Starter
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Default Simple solutions are always the best answer

My latest project requires a belt drive and therefore I needed a couple of pulleys. This isn’t a machine with a lot of stress so simple wooden pulleys will work just fine.

I thought long and hard about how to make them and went through the mental design of some exotic hold-downs for the router table. In the end I settled for a simple auxiliary fence that would keep a long dowel at a right angle to the regular fence. A 2” diameter dowel was aligned along the extra fence and lowered onto a 90º bit that extended about 1/4” above the table. Turning the dowel clockwise cut a groove and then the grooved end of the dowel was sliced off with the bandsaw to give me a nice pulley.

The next problem I faced was tapping some nylon bushings to take a 10-24 set screw so they would lock down on a shaft rod. I tried holding the bushing in a small drill press vice but the bushing kept moving from the pressure of the drill bit.

So, another simple solution was required. I drilled a hole that fit the bushing and its collar into the face of a piece of scrap poplar and also drilled a hole on the top of the little jig edge to align the drill bit for the tap hole. (See the photo, it makes more sense than the words.)

With the little jig clamped onto the drill press table I was able to quickly drill the five bushings I needed. Tapping the threads into the nylon also went quickly and I was done. I need to be sure the bushings that fit the pulleys cannot slip when the shaft turns so I recessed the bushing collar into the face of the pulley with a 7/8” forstner bit. Sanding one edge of the collar flat leaves a little gap I’ll fill with epoxy and the bushing won’t be able to turn on the face of the pulley. (Again, the photos tell the story better the words.)

The final photo shows the gears and pulleys for this project. Assembly is getting closer. More about making the belt for the drive later.
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kp91, JFPNCM, chessnut2 and 13 others like this.

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post #2 of 17 (permalink) Old 10-29-2016, 12:22 AM
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Nice work Oliver.

Someone I consider a master woodworker once told me that a master woodworker is not someone who never makes mistakes. He is someone who is able to cover them up so that no one can tell.
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post #3 of 17 (permalink) Old 10-29-2016, 12:33 AM
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you never fail to impress me Oliver...

This would have been the week that I'd have finished chewing thru the restraints...
If only new layers hadn't been added....

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post #4 of 17 (permalink) Old 10-29-2016, 01:53 AM
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Quote:
Originally Posted by Gaffboat View Post
My latest project requires a belt drive and therefore I needed a couple of pulleys. This isn’t a machine with a lot of stress so simple wooden pulleys will work just fine.

I thought long and hard about how to make them and went through the mental design of some exotic hold-downs for the router table. In the end I settled for a simple auxiliary fence that would keep a long dowel at a right angle to the regular fence. A 2” diameter dowel was aligned along the extra fence and lowered onto a 90º bit that extended about 1/4” above the table. Turning the dowel clockwise cut a groove and then the grooved end of the dowel was sliced off with the bandsaw to give me a nice pulley.

The next problem I faced was tapping some nylon bushings to take a 10-24 set screw so they would lock down on a shaft rod. I tried holding the bushing in a small drill press vice but the bushing kept moving from the pressure of the drill bit.

So, another simple solution was required. I drilled a hole that fit the bushing and its collar into the face of a piece of scrap poplar and also drilled a hole on the top of the little jig edge to align the drill bit for the tap hole. (See the photo, it makes more sense than the words.)

With the little jig clamped onto the drill press table I was able to quickly drill the five bushings I needed. Tapping the threads into the nylon also went quickly and I was done. I need to be sure the bushings that fit the pulleys cannot slip when the shaft turns so I recessed the bushing collar into the face of the pulley with a 7/8” forstner bit. Sanding one edge of the collar flat leaves a little gap I’ll fill with epoxy and the bushing won’t be able to turn on the face of the pulley. (Again, the photos tell the story better the words.)

The final photo shows the gears and pulleys for this project. Assembly is getting closer. More about making the belt for the drive later.
Pretty to watch,with sore eyes even

You can't drive a bridge spike with a tack hammer(so I'm told)
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post #5 of 17 (permalink) Old 10-29-2016, 06:32 AM
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@Gaffboat

You can accomplish the same thing by drilling a hole on the circumference of the bushing flange into both the bushing and pulley and installing a piece of 3/16" (?) dowel to give you a circular key (or 2 @ 180° if you need the additional torque capacity).
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post #6 of 17 (permalink) Old 10-29-2016, 08:07 AM
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Some very nice work Oliver. Well thought out.

When the enemy is in range, so are you.
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post #7 of 17 (permalink) Old 10-29-2016, 08:49 AM
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+1 what Stick said. I think henceforth you should be known as the Amazing Oliver.

"The difference between genius and stupidity is that genius has its limits". Albert Einstein
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post #8 of 17 (permalink) Old 10-29-2016, 09:53 AM
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The man is clever, that's certain.

The more I do, the less I accomplish.
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post #9 of 17 (permalink) Old 10-29-2016, 10:38 AM
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Great creativity! It's always fun seeing what you can come up with when you decide to 'just make it work with what I have on hand'. Some are photo-worthy and some don't need to be mentioned again; this one is photo-worthy.

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post #10 of 17 (permalink) Old 10-29-2016, 10:55 AM
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I need to start an Oliver folder and store all your stuff in it...AWESOME...
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