Introduction: Pulley Remover Tool From Scrap - Quick'n Simple
Let's start on the beginning.
This is my first year at electrical university and i moved to a city nearly 130 km away from my home. Therefore i decided to stay in the college dorm. And there the story begins.
In our dorm, we have an annex next to the building (i don't know if annex is a proper word) and inside, there is a small abandoned workshop, i believe woodworking workshop (a lot of hand tools), that still contains many useful items. I mean, a lot of junk stuff that can be used in different "reusable" projects and some leftovers and still useful things). I noticed that there was this little table saw in rather poor conditions. If i can call it table saw at all. It has just a flat wooden base and a well-worn-out saw blade (many of saw teeths was broken, some was even missing). It seems like a homemade build version. You couldn't even make a straight cut hence no support rail or whatsoever. The one thing i like was a big and over-sized (and i mean it, for .7 kW one-phased) motor, and it has two speeds. I thought it could be fun to make something useful out of it. And when i got a time to spend outside the circle of kitchen, studying and university, i made a first step forward. I will probably make another instructable of making that table saw but that is in the future.
The first move? Bearing replacement in that motor. Aaand there it goes the problem. Pulley.
And when you are a student, with just a few tools by hand and so desperate to remove the pulley from an electric motor to replace motor bearings.. Oh, you've been there, huh? Well, let's see how i solved the case.
Step 1: Mystery Shaft - Short Peek
... as i call the abandon workshop. Its behind the first door. Our "new" workshop-ish place is behind the second door (and we - students from our college - also stores bicycles there)
Step 2: How You Should Remove Pulley, My Work and Results - in Video
Hence i don't know much about creating animations and such, i made a time lapse of me, drawing. I apologize for a bit shaking but i held my phone partly in my mouth (actually the strap of the cover) and partly with my hand.
I have a sh*tty drills (especially the big one) so i had to improvise a bit when i was drilling holes. Please note that this is re-assembly of pulley remover since i already disassembly the pulley and the motor. But anyway, enjoy.
And why cornflakes? Well, when i finished, a midnight snack came in handy.. at 2:45 a.m. ;)
Step 3: What You'll Actually Need
There is nothing special. I used a wrench, a pliers, a few different drills, ruler tape and an angle grinder. You can use hacksaw as well instead of a grinder. It's always welcome to have a hammer to release all inner peace when things go not-so-well. Try not to broke anything valuable or vital!
Another thing i recommend is some kind of coolant when you are drilling holes (i used WD40 - penetrating oil, you can use a bunch of different ones or get a professional coolant for that purpose)
Step 4: Gathering Stuff
The first thing i did is to look around inside a mystery shaft. I found exactly what i was looking for. Almost.
I found two fairy long M12 (iso) threaded rod. I found exactly two nuts that size. I needed three so i took one off from an old bench wise and reinstalled it when i was finished.
I found two identical metal flats with two holes, just the right size for my purpose. It seemed to be grinded off from something in the past.
Later on, i found a bit smaller and thinner metal flat and i strengthened the main support with it. I found a bunch of just long enough screws (M8 i believe, it would be better if i got two M10 screews or four M12 nuts) and a bunch of M8 nuts. But it was what it was.
I found a small alu tube on one of that screws so i used it as a spacer because of too large side holes in the main. support. There was even one (only one) big washer.
Step 5: Processing
I cut in a half one of two thick "two holed" flats and used both halves as a clamps/jaws/whatever should i call it. Next thing i did was to drill a hole into another one metal flats (i called it the main flat) for the big threaded rod to go through. I repeat this process with the thinner metal flat and used it as a support to prevent bending because of deep cuts in the main metal flat. The last thing to do was to cut an aluminium tube in half and pressed it in the two small holes in the main flat.
Confused? Let's take a look at the picture.
If you wonder how i put it all together, take a look at the video above (step 2)
Step 6: Give It a Shot
Well, nothing much left to say - clamped in, turning a nut to move up will slowly pull up the pulley
Step 7: Result
That would be all of it. If you have any questions, feel free to ask. There is place for many improvements but that is how i did it and it worked.
But for now, best wishes from Slovenia.