Mrs 3Ltr stopped today

[solarman216]

Yes called out to the 3lt today amongst all else I had to do, popped the bonnet and did not like the angle of the serpentine belt, got the torch out and seems the alternator pulley was not where it should be, I was a bit dubious about starting it first, not wanting it to come off and do more damage but looking at the belt realised all the time the belt is tight it would keep it in line roughly, so jump started it and sent the Mrs on her way home.

So can somebody tell me why oh why these ridiculous free wheel pulleys are used? a free wheel will not be going back I can assure you, Rick

[panelbeater]

my alt went when away with my cvan and i got one in chesterfield.i had not seen one like it but easy to take off and exchanged it for replacement alt which came with new pully fitted.i think its to do with when starting it breake the sudden load on alt,could be wrong though.so you might need a new alt.

[Banshee]

Nightmare Rick!!!

Glad it wasn't terminal, some pics would be good when you come to do the job.

I was stripping a 3.0 ZD30 Patrol engine down for parts last night that I picked up from London a while ago when I picked up the Y61 axles and Front Winch Bumper for my Patrol.

I've been in touch with a lad who seems to be active more over on the Facebook group side of things and he asked me for a Power Steering Pump for his Terrano ZD30 and the part was identical physically (or so we thought)

After some research, it appears that the Patrol ZD30 pump is actually higher output, which you'd kind of expect really with all the extra weight compared to a Terrano.

This gives me a lot to think about if I do come to transplant a ZD30 into my Y61. It's not looking good with my head that's gone away for repair as they still haven't managed to get my broken glow plugs out :doh

So me and Flying Torquewrench have stuffed it :(

[solarman216]

OK so this is the problem with the alternator, this is where the pulley should be

[solarman216]

And this is where it was when I saw it on the car, but after starting it the belt pulled it back but the alternator was barely charging due to slip

[solarman216]

Shim inserted to hold the brushes

[solarman216]

Com is in good order

[solarman216]

The two bits

[solarman216]

Broke bearing

[solarman216]

Calliper on top part of shaft

[solarman216]

And bottom, not a clear pic but about 1mm smaller

[solarman216]

The mess from inside the pulley

[solarman216]

So stuck the armature on the lathe to make it parallel again

[solarman216]

Now all good again

[solarman216]

Now all I need to do is make a good fitting bush to fit between these two

[solarman216]

This is the stock that it will be made from, took some hunting down as I needed steel not cast, this is a roller from an old pipe bender, but not today, job for tomorrow, Rick

[panelbeater]

great set of picks rick,never seen inside one of the pulleys.

[Banshee]

Lovely stuff Rick!!!

Can't beat the old school tools

[solarman216]

Back on it today interspersing with directing tree surgeons, so this is boring the shaft hole aiming for 1Thou smaller than the shaft

[solarman216]

Bore done now the outside, had to do it in two halves as the bore would not quite go over the internal chuck jaws

[solarman216]

The finished bush about to be pressed into the pulley

[solarman216]

Pulley and fitted bush to be pressed onto the alternator shaft, took the full 6 tonnes of the press to push it home, well pleased with that as no need to weld

[solarman216]

The finished job, and the Mrs is now mobile again, Rick

[Flying Torquewrench]

Looking good Rick. Bit of proper engineering. :thumbs

[solarman216]

OK so been doing some research re free wheel pulleys, the upshot is this, because serpentine belts have a self adjusting spring loaded pulley, which is crap, they had to find a way of stopping the pulley jumping under certain situations, idling is one, so they came up with the naff idea of a rubbish free wheeling pulley which smooth's out the the irregular crank rotation on the alternator as it's mass is quite high, never had a problem with fixed adjustment V belts, so next mod on the Mrs motor is fix that ruddy springy pulley and make the alternator the adjustment point, Rick

[panelbeater]

pullys are on line from 25 and full alts from 80,just saying for any others that might need.yes good job there rick,my lathe would not go that big as its more a model engine lathe.

[terranosaurusdoug]

Nice one Rick, I wish I was set up like that :thumb2

[panelbeater]

can i suggest that a spare belt be carried as making it a fixed pulley will put the most strain on the belt as its design is not like a v belt thats designed to stretch and dig into the v for extra grip under load.

[solarman216]

Nice one Rick, I wish I was set up like that :thumb2

Got a guy down here with a mini digger, the bushes in the end of the main arm were none existent and so the bore had worn so much new bushes were not the answer, so he produced a lump of metal that had been used as a slide hammer, what was required is 61mm ext diameter by about 100mm long with a bore of 33mm, problem is the hole that had been drilled for slide hammer use is not central or parallel, started to machine it up today carry on with it tomorrow, if anyone interested I can post some pics, Rick

[Flying Torquewrench]

What lathe have you got Rick? Looking for one myself but not sure if I go second hand old school or brand new.

[solarman216]

Only a Myford Super 7 with screw cutting availability, sadly not big enough for skimming brake drums or disks but I would not want to be without it, Rick

[solarman216]

There is one on Ebay now for £1600 with stand, looks good, Rick

[Flying Torquewrench]

Very nice. The old British made lathes are certainly commanding a high price these days. It is difficult to spot a diamond in the rough that is nice an straight.

I have been looking at a Warco Gear Head lathe. Chinese made :o but Warco’s service is very good.

[solarman216]

Mmmmm lots of bells and whistles, depends on what you want to use it for, Rick

[solarman216]

Same digger guy gave me today a chunk of metal that is apparently a track roller for a 3 ton digger, it had been welded up and now needs machining to accept a couple of bearings, will post a pic tomorrow, not sure I can do this on my 63 year old machine, yes looked it up yesterday, nearly as old as me, Rick

[Flying Torquewrench]

Mmmmm lots of bells and whistles, depends on what you want to use it for, Rick

I make/adapt a lot of the attachments for my digger. Being able to make my own bushes, pins etc. is so much more convenient. A lot of the bells and whistles won’t be used but the one I am looking at has a 910mm between centres. Rather go for a bigger machine now and be able to “grow” my work into it then ending up buying a bigger machine later.

Put up some pics of the work on the digger when you have time.

How is the London cab coming along?

[solarman216]

London Taxi went home a week or so ago, to have the MOT done once the steering has been fixed by a specialist Taxi engineer, Rick

[Flying Torquewrench]

What was wrong with the steering? Not often that there is something that you can’t fix.

[solarman216]

This is the ghastly lump of metal that my mate thought I could put right on my lathe, this indicates how out of true it is, look at the gap between tool and job

[solarman216]

Now look at the gap

[solarman216]

That was over 180 degrees, so I found a lump of scrap brass and made this up to try and centre in the chuck to try and turn the outside in order to turn it round so the now centred part was in the chuck but the other end was miles out so it is a no go, Rick

[Flying Torquewrench]

I really don’t understand why the digger guy doesn’t buy a new track roller. Obviously I don’t know what make/model machine it is but you can get them for under £100 for the cheaper ones and up to about £150 for the more expensive versions.

[solarman216]

I do not know the make and model but it is old and apparently no longer available, Rick

[Flying Torquewrench]

That’s fair enough Rick. You have your work cut out trying to polish that t*rd. :eek:

[solarman216]

Seems this machine lives on a farm and if it tracks 500 yards a year it is a lot so just need to get it mobile ie get a couple of bearings inside it, the outside does not matter, Rick

[solarman216]

Just ordered a 100mm X 100mm billet of stock metal to make a new roller akka last posts on Mrs 3Ltr stopped today as it was a hijack of that thread, as and when I get delivery I will post pics, got to try and keep interest up on this forum, Rick