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This is the shaft of a Jet 16'' planner motor bought in March 2014.
The key slipped on the shaft this is the result. Now before you say
I hog out to much at one time NO that is not the case. I take small
bites a half to a quarter turn per pass. I called a motor repair and they
could fix it, but said it would cost same as a new motor. So $500.00
later I have a new motor.
 

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John
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Just looks like metal fatigue to me, just a bad metal tempering job
 

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Ouch! Looking at the length of the keyway, that was a short key as well... might have been a contributing factor.

Really a moot point now that you have the new motor, but if you know a welder, I don't think that would have been that difficult to repair.
 
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For a motor of mine, I would dis-assemble it and take the rotor and shaft to a friens's machine shop, cut a new keyway on the opposite side of the shaft, re-assemble the motor with a new key and pulley, using blue Loctite on the set screw, probably backing up the set screw with a second on on top of the first to lock the first in place, and put the motor back into service. No way would I buy another motor if I could save this one.

Charley
 

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For a motor of mine, I would dis-assemble it and take the rotor and shaft to a friens's machine shop, cut a new keyway on the opposite side of the shaft, re-assemble the motor with a new key and pulley, using blue Loctite on the set screw, probably backing up the set screw with a second on on top of the first to lock the first in place, and put the motor back into service. No way would I buy another motor if I could save this one.

Charley
Good idea, Charley. :smile:
 

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Theo
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For a motor of mine, I would dis-assemble it and take the rotor and shaft to a friens's machine shop, cut a new keyway on the opposite side of the shaft, re-assemble the motor with a new key and pulley, using blue Loctite on the set screw, probably backing up the set screw with a second on on top of the first to lock the first in place, and put the motor back into service. No way would I buy another motor if I could save this one.

Charley
I know there is a way to rescue that, but can't recall just what it is now, but does involve seeing a machinist. Not your way, but your way should work just as well. A machinist might even know a different way to fix the problem. I'm like you, I would definitely take it to a machinist first.

Somewhere along the line I recall someone drilling thru the pulley and shaft, and putting a bolt thru them. As far as I know whatever it was no more problems with it. I think it was the pulley that went somehow. Don't know if I would recommend that or not, I suppose it would depend on circumstances at the time.
 

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Putting a bolt through the pulley and motor shaft is a good way to destroy both the motor and pulley. There would be no way to tightly join the motor shaft and pulley, and they would tear each other apart in a short time. They repair shafts with bad keyways on very large motors by welding up the damaged area of the shaft and then machining a new keyway, but for a small motor, just cutting a new keyway on the opposite side of the shaft is usually the easiest and cheapest way to save the motor.

Charley
 

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I agree that that was repairable. I worked in sales for a machine shop for 1 1/2 yrs and saw some of the older conventional machinists work miracles. Weld to rebuild surface using appropriate welding materials and procedures, then machine to re balance and finally re-cut a new key way. I would still have it done to have a back up motor. The cost would not be anywhere near the new one.
 
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