Electric Assist Project: E-charger (2000 Subaru Outback)

[Dr. Jerryrigger]

Originally Posted by brucey

Pulley showed up today...

I hope this is just some misunderstanding on my part because otherwise it's an awesome piece of work. Looks like it will fit with a little heat pretty easily. Hopefully I will still be able to use this one.

sweet, that's rather beefy. Is it aluminum? If so be careful heating it...

[brucey]

Ordered a keyshaft that should be the right size. Along with a split collar to lock it all in palce.

Hopefully this should be it.

[ShadeTreeMech]

Did the pulley fit on the shaft? I'm certain you know a precision fit will be extremely difficult to get perfect--if I were your pulley man I'd want the motor in my lap to get a precise measurement. Even if you both have good quality calipers, even .002 of a difference between the calipers will be problematic. and 2/1000th of an inch is very small. For a custom job, a measurement done on 2 parts with 1 good quality caliper is a billion times better than a measurement done with 2 better quality calipers.

[brucey]

It looks like it will fit well. It is tight on there, in fact, so tight I'm afraid when I do mount it I'll never be able to get it back off. He suggested heating it at 300 degrees for 2 hours before mounting it to help it expand some.

It's pretty close to a perfect fit really. The shaft is 7/8" so I think that helped.

[ShadeTreeMech]

if he said heat it to 300 then the snug fit must have been by design--a clever design really. A part with no slop would nearly never wear out!

[brucey]

I can actually put it on the shaft about .5" but then it's a pain to get back off. But just from that, I can spin the motor shaft itself quite quickly and even stop it without the pulley spinning. With the key rod in there and a collar on the end holding it all tight, I'm not going to be worried about it.

I'm hoping the belt has enough power to spin the motor up still, but I did get the pulley with 10 ribs in case I need more belt area. It should still work with the normal 5 rib I have however, I just have the option of upgrading if necessary (: Although I guess I'd have to upgrade the belt, the crank pulley, the PS/Alt pulleys too. Hopefully shouldn't be expensive if necessary.

I still haven't started on the wiring at all. I was wanting to get my block heater in and the teardrop finished before resuming work on this.

[brucey]

Just a quick update since I know there are some people waiting for this:

I had to order a split collar and a keyshaft to install the pulley. I know I should have done that sooner but well I forgot. The collar arrived 2 days after I ordered it, and the keyshaft still hasn't even shipped.

Bahumbug.

[ShadeTreeMech]

grr, always hate waiting for parts.

But you know the adage, do you want quality, speed of service, or a great price? You can only pick 2.

[brucey]

I always thought it was sexy sane and smart. Pick 2.

[cmj]

I was only aware of Cheap, Reliable, Fast (pick two)

P.S. This thread is awesome. I'm excited to see where it takes you (hopefully a lot further on less fuel!)