you certainly know your stuff! whats rc mean?

units of the rockwell scale

the rockwell test calculates a value of hardness using the increase in depth of penetration of a given load. Easier to understand if you see it being done. Basically what sort of impression a uniform load leaves on a material.

Milgo - Are you making a standard sized pulley? If your making a reduced pulley what the spec and how much to knock up another one

As giorgio says ^^ :)

Was just an illustration to show the difference between the two materials. What I find weird is hard anodizing can create a really hard surface, so the finish on these pulleys must be pretty thin.

For now i'm re-making a standard one as a test really. I want to see how light I can get it out of steel. Plus the other problem with making it smaller is that it will have to be constructed in sections. The wire would hit the bearing face when cutting the pulley profile, so either copy the psd design and have a bearing sleeve or make interchangable ends.

If I made a batch it would be from some good grade ally properly anodized to a decent hardness. I think you can get it to 70rc or so. But I'd have to work out the pulley size and it wouldn't be dirt cheap as i have to pull in some favours. Would depend if a few people were interested and if they were realistic with prices. Although not sure if psd have some sort of protection on the design?

Although not sure if psd have some sort of protection on the design?

As far as I know there are no patents etc on the PSD Kits. I am no expert but if your making a reduced pulley, thus changing the design, you wouldn't get in any trouble if there was.

To be honest I don't think there are many people running eaton to make a batch production worth while.

Here are the pics of the mounting bracket. It bolts to the exhaust manifold and a threaded rod goes into the bracket. he other threaded rod goes through the eaton. One nut goes before the 'eye' on the eaton and one on back. If you don't use Nyloc nuts then use 2 to lock them off. Am working on the golf this morning, supposed to be there at 8am , but if I get a change I will take the bracket off and give you measurements.

Dare I say it but I would probably redesign it slightly as the rod doesn't sit perfectly square

All the pics I took were before the bracket was fitted, then last weekend I gave up taking photos so here is my detailed Catia drawings........

There was

Hey cheers for the picture! Looks nice and simple to make.

Just a little update on the pulley, progress is slow as i have to work on it in between other jobs.

Holes drilled and reamed for dowels:

Test fit, all good Slightly tighter fit with my pulley, which is probably down to using a worn reamer. Hard to find a 1/4" reamer when everything is metric. Fingers crossed the dont shift when i heat treat it.

You can also see i have bored out a lot of material from the front. Weighs in at 850g so far compared to the 350g aluminium pulley. With the rest of the material out i've calculated it to weigh around 600g which i am happy with. Stainless pulleys on the mini weigh about 650g. Don't think rotational weight plays a huge role in small pulleys but still worth slimming down.

Edited 25 June, 200818 yr by milgo1

Finally a little progress. Been a bit of fiddling getting the dowel holes all central etc so had to bore the hole out bigger in the middle to get it all spot on when it comes to grinding. Measuring the original the holes are actually out slightly, 0.1mm infact which i think is rather a lot. I'm aiming to have the bearing face running within 0.02mm to the dowels.

So anyway, today had the teeth cut and came out spot on which is great for a first try. Only measured the teeth with verniers and putting dowels in to work out the diameters etc. so it was a little guess work.

Now just got to lighten it some more and it well get heat treated, ground and made pretty.

Ello mate. Good build thread this, should be a great car once finished

Do i recall you mentioning you worked at Dagenham, when you were at the Polo Show '06?

Hey, yeah thats right mate. Can't believe that was so long ago now.

Yeah hopefully once i get an engine the thread should pick up pace :) a little slow moving at the moment.

Edited 4 July, 200818 yr by milgo1

are you making some form of end cover plate for the intake end of the eaton?

What do you mean? A plate to cover the waterpump gears? Or an adaptor for the inlet?

Very impressed with the machining you have carried out so far.

It will undoubtably be a very tight fit getting the Eaton in the confines of a mk1 bay. It'll more than likely stick out the front panel - quite a lot in fact! Where the hell are you gonna fit the intercooler and oil cooler!!??

Keep up the excellent work milgo,

Cheers,

Richard.

ta breadman :)

Yeah i expect it will stick out a fair way, perhaps not as bad as you might think though. We will see in time :) I will probably be kicking myself down the line and moaning at how much effort it is to fit. I will probably fit a custom rad, or maybe just get away with a standard one with a slimline fan. I was thinking the intercooler might get tucked under the front panel and then make some sort of scoop to feed the air up to it. Not really a fan of the front mounts that sit in the front of the cars front panel. Probably use a faily small intercooler and squeeze some water injection in there to compensate. No real planning involved :) just lots of trial and error, which is how i usually work.

What do you mean? A plate to cover the waterpump gears? Or an adaptor for the inlet?

now you mention it how are you doing the intake?

Not sure if its the water pump gears but they are just below the inlet.

This looks great,top bit of engineering and a promising plan.

I've suggested tilting the engine back a touch previously,but i doubt it'd make much difference in this case..

It'll be nice to see this progress

Still not sure what i'm doing with the inlet side of things. I've had a few ideas, but the shape is so awkward. Probably best way will be to machine some of the charger or weld some of it. But for the gears at that end i'm going to draw up a plate and have it laser cut from aluminium. See what it comes out like anyway, unless its good quality metal the laser just makes massive burrs.

I'll look at tilting the engine mikey, that free up some valuable space.

if your tilting the engine then it may be an idea to use a Seat Cordoba front gearbox mount. You will need to fabricate some brackets, probably off the chasis legs, although it will give you the stability and the ability to tilt the engine.

I am off to change the alternator on my car so can grab you some dimensions.

also get onto clubg40.co.uk

any more updates on this???

fook me - thread resurection! i doubt it- i thought this got sold

on long ago. iirc the charger went on ebay along with the new pulley.