NeilP said:
I'd avoid ANY welding, use DP 420 if you have to,
And clamping torque plates/clamps, if they are fixed, going to cause problems
What kind of problems?
You are going to have to source or make your own new side cover for the sporocket.....
That's probably not a problem; I'll do what I did with a 9C front: reuse the threaded side of an old regular hub, and bolt it's flange to the sidecover. Freewheel threads onto that.
So the limiting size of my axle would be the center of the old hub's core.
have you heard of 'sprag bearings'
http://simplybearings.co.uk/shop/Bearings-.-Needle+Roller+Clutches/c3_4474_4508/p12408/Branded+HF3020+Needle+Roller+Clutch+Type+One+Way+Bearing+30x37x20mm/product_info.html
One of those, with a 25mm internal diameter bearing
http://simplybearings.co.uk/shop/p1072/Major+Branded+618052RSR+Rubber+Sealed+Thin+Section+Deep+Groove+Ball+Bearing+25x37x7mm/product_info.html
Might be a possibility, but if I can use the existing bearings I'd rather do that, assuming that the hole in the freewheel/hub section is no bigger than that anyway. The only sprag bearings I already have here are far too small a diameter (off an old exercise machine).
Bearings with a bolt in freewheel clutch
Since the limiting factor to the diameter of any axle is the sprocket and freewheel mech, you have an opertunity here to beat that limitation, by making your own side cover with fixed sprocket sprag bearing carrier unit.
Yeah, the catch is as usual money. I'm not sure I can afford all the stuff needed to do it, or that it would all be worth it once I was done, anyway.
(assuming I can even do it without screwing stuff up and having to redo it more than once, which could greatly increase it's cost).
Still, that's why I'm investigating, and asking.
I may find it's far cheaper and easier than I thought it would be.
(at the moment it seems like an incredibly complex undertaking as I start mentally cataloguing all the steps)
Confused by two statements you make. You say you won't be able to press an axle in, but then you talk of making your own hydraulic press ?
To press the existing axle out--that ougth to be easy enough. But to press *in* the new axle, alignment has to be better, right? I'm not sure I can guarantee that. I'd rather not screw it up and damage the stator, cuz that's a part I probably can't fix.
I've never made or used a press before, though I've seen the harbor freight ones that basically use a car jack and some I-beams. I don't have I-beams, but I have square tubing, round tubing and thick piping, and a welder, and I can probably make somethign reinforced well enough to take the loads. If not, it should be an interesting failure, at least. :lol: My car jack is also different than theirs--they use a bottle jack and mine is the lever style. (which may be a bottle jack as it's basic core, but I'm not sure it can come apart in a way that allows it to be reassembled to it's original design).
I'd also have to figure out splines or knurling that I could do manually on my little 80-year-old SouthBend lathe that while it works for basic stuff, I don't think I have all the parts for (and I am still learnign how to use it). I am pretty sure I can use the threading/gearmaking part (whcih I have part of) to force the tool holder to traverse a keyway into the center of the axle, whether hollow or solid, while the axle is just clamped to the bed and non-rotating. .
Cost is a really big factor, too, so I can't go out and buy new tools for the job.
With bigger diameters, you can avoid a hollow axle,and make two piece like I did.
I'm gonna have to get the motor apart again and all my bits together, and start measuring things to see what I can actually do with what I have here. It seems like the hollow axle would be easier to make and deal with, especially with the limited tools and primitive skills I have available.
But I could be wrong, as I don't have a machinist mindset yet, and am unsure of processes and orders of actions to do any of this so far.
If you have to make one new side cover, what the hell, make two, one for the other side too, then you can make the central bearing boss bigger there too for bigger bearing
If I have to use bigger bearing holes in teh covers, I'd just machine them into the existing covers. There *appears* to be enough meat to them to do that, for antying that would fit thru the existing hole in the stator anyway.
Making new sidecovers might be possible, but they'd have to be made out of whatever plate steel I have around here, most of which is not that thick. I would liekly have to bolt or weld layers together to make the different sections of it (bolt-flange to attach to rotor would be a ring, then another ring overlapping that that goes down to the bearign area, then either weld that to a large-diameter pipe section, or a set of flat plate-rings that would bolt or weld together to be thck enough to support bearings/etc.).
My lathe bed isnt' very deep, not enough I think to do the covers, so either I'd have to build somethign to extend that by putting the spindle up higher. Then the chuck isn't all that big, either, so to do larger diameter stuff I'd have to start from the center pieces and build up from there, so the chuck has something to hold onto to ensure it's all centered and circular relative to each other's centers.
Or just manually cut and file all the cover rings/discs/etc. Definitley not looking forward to that much hand-work (my hands don't always work well enough for it, so ti can take a long long time).
