Decided to finally finish my single pulley conversion piece for the 3.6 motor. For those who don't know the 3.6, it uses two separate pulleys/belts for the fan and the Alt. The 914 motor mount doesn't allow for this and you have to convert to single pulley. You can buy the single hub from Patrick and I'm sure others, but if you have a lathe and a mill and a couple of hours to play........viola......

You make this:

From this.........

Here's with the fan/pulley.......

Here's mounted and finished........

Lathe, mill, and from the looks of it - a keyway broach too.

Very slick. Machinists are cool.

-Ben M.

No keyway broach, as there is no keyway! It's actually a pretty simple part. I saved the drawing in case anyone wants to make one.

I thought that was a keyway too. I can see that it bolts to the crank and the "slot" cut is for the pulley -whats the correct terminology for it?

They're actually just clearance cuts so you can access the pulley nuts with a socket. Without them the socket wont fit between the nut and the hub and you'd have to use a wrench. The 911 alt/fan belt is adjusted by adding spacers between the pulley halves. I couldn't imagine trying to deal with these nuts blindly with a wrench to change a belt once the motors in. These reliefs were cut with a 5/8" end mill bit.

Sorry.......meant to attach this pic! Arrow shows the relief area around the nut.......

Ben,

for an internal slot with 90° corners, a broach is used, for external, a small cutter similar to a saw blade used on your table saw is used (for woodruf keys and such)

looks nice, glad to see I am not the only nut here that wishes to make my own parts instead of buying them