The other night I started working on the key for the pulley. I chopped it out of some 3/8" plate I had kicking around. It still needs to be trimmed up a bit, but I ran out of grinding wheels, so that'll get finished up another night.
Here are the pics:
As mentioned, I cut this out of 3/8" plate. Its supposed to be 1/4" x 3/16" x 1-1/2", so it took some grinding. I just went at it with an angle grinder to get it to shape. Trial fit, then grind some more, trial fit, grind, rinse repeat.
Then, I drilled two 1/8" holes. These aren't the right size for the #6 tapped holes, but its what I had and its close enough.
With the holes drilled, I could tap them.
And here we have it assembled. The key fits great and does its job. The pulley actually fits a bit looser than I'd like on the shaft. I must not have double checked my dimensions before printing. It will still probably work.
Here is everything bolted up to the motor. As I mentioned, the key still needs to be ground down in the middle so the nut fits on all the way. But, it all goes together quite well. I'm happy with it.
