The video channel “E+M” shows the technology for manufacturing pulleys from simple and available materials using available tools. In this case, we will do without a lathe. In the second part of the publication there is another technology from another master.
Let's start manufacturing. To make type 1 you will need the following materials. Superglue, sheet metal, linoleum, hot glue and a bicycle spoke.

We begin production with markings. To do this, set off the desired radius with a compass and ruler. Draw a circle on the metal. Now we set aside another radius, but one millimeter less than on the previous disks. Draw a circle on the linoleum. Drill a 2 mm hole for the axle. We apply the center of the disk and linoleum to the center of the tin. Turn it over on the other side and make holes through the stencil.

The axle is made from a bicycle spoke. To bite off, use side cutters or pliers. We assemble and connect the parts together with glue. Since you are turning, we fix it with hot glue. The photo shows an example where a similar pulley is used.

There is an engine from washing machine. Its power is enough for non-professional work. The turner lengthened the shaft and made it symmetrical on both sides. Now the task is to make a drive pulley without involving a turner. Diameter 95 millimeters. Ten plywood. Use a jigsaw to cut out 5 circles. Diameter 100 millimeters. We will connect the blanks with glue, place them on the shaft and grind them. It turned out that the thickness of the plywood is 12 millimeters, so 5 disks are enough. Total thickness 60 millimeters. Since we plan to use a standard belt for sanding machines, such a circle is sufficient for the width of the belt.

In 3 circles feather drill drill holes. The diameter of the shaft is 14 millimeters, so the drill is 12. Put it together. Apply glue and secure with self-tapping screws. After all the manipulations, the result was a pancake. Its thickness is equal to the thickness that we want to put on the shaft.
The shaft diameter is almost 2 millimeters larger. It is necessary to maintain alignment, since there are still differences inside. Insert a round file inside. Holding the file on both sides with your hands, we lay the wheel several times. How to increase the internal diameter and maintain alignment.

After these procedures, we take the two remaining circles, glue them together and fasten them with self-tapping screws. In this way, you can make not only the drive shaft for the grinder, but also a flange for the emery stone. Or any other attachment for sandpaper.

The roller was mounted on the shaft. We will grind with the engine running. The centering of the shaft itself is also not one hundred percent, but this is not critical. If you want to make such a shaft, you can definitely use glue. Do not hit the pulley directly with a hammer, only through the mandrel. You can use a piece of plywood. Slowly, with light blows, he pushes on.

Doing something homemade device on a belt drive, you often encounter the problem of a missing pulley required diameter. Finding it on the market or through friends takes a lot of time, and it is not yet a fact that it will be found. And not everyone has a familiar turner. In most cases, I solve this problem on my own.

What can you make a homemade pulley from?

Of course, made of plywood. If you don’t have a lathe, you have to choose from available materials. Wood is not a reliable assistant in this matter - it can easily split. But dense plywood copes with this task quite adequately.

Depending on the size of the pulley, I select plywood optimal thickness. I cut out three circles from it, two of the same size, and the third a little smaller (the thickness of the V-belt). Also, I immediately drill a hole in each of them - strictly, in the future they will be very useful.

I clean them as much as possible, first each one separately. Moreover, on two identical circles, I chamfer one side at approximately 45 degrees. Cleaning is easier and better if you put a circle on a large nail.

I assemble sanded plywood circles onto a bolt with a wide washer placed on the head. I try to select the bolt itself with such a diameter that it fits snugly into drilled hole. I collect circles in the sequence large - small - large. Large ones are chamfered inward.

I smear PVA on both sides of the smaller circle, assemble the future pulley and tighten the bolt with a nut and a wide washer. And I leave the whole thing to dry well.

Although PVA glue holds the parts perfectly, for reliability they can be fastened together with self-tapping screws. Just screw them into pre-drilled thin holes.

Now the pulley just needs to be modified a little. If it is of small diameter, I insert it into a drill mounted on the table and first process it with a large file, remove the unevenness of the circle and smooth out the chamfers. And I finish the treatment with sandpaper. If the pulley is large, I put it on the electric motor and carry out the processing directly on site.

The pulley is a very important part of any machine tool, allowing you to regulate the speed and load on the motor. The good thing about making a pulley yourself is that you can make a pulley of exactly the size that is needed and strictly for the shaft of the existing engine.
It is recommended to make pulleys from metal or textolite. It is not recommended to make pulleys from wood, since such a pulley will fail as a result of heating and wedging forces. A plywood pulley is a cross between metal and wood, easy to manufacture and quite durable. Such a pulley can be used in the manufacture of homemade machines.

So, you need to cut three circles out of plywood, two larger and one smaller. To do this, first mark the circles with a compass (the centers of the circles should also be clearly visible) and cut them out with a jigsaw. The centers are drilled according to the diameter of the shaft on which the pulley will be seated. For the convenience of further work, the circles can be placed on a screw and tightened with a nut, or glued together.
Next, the circles are tightened with screws, as shown in the figure. The almost finished clamping pulley is inserted into the drill chuck, after which the pulley rotating with the drill is processed with a narrow file and sandpaper. The completed pulley can be oiled. That's it, the pulley is ready!
Attaching the pulley to the shaft depends on the circumstances.
When making a pulley, it is important to ensure that the center of gravity is on the axis of rotation, otherwise vibration cannot be avoided.
If you have a timing belt, you can make a timing pulley for it. To do this, before assembly, teeth are cut on the central circle (of course, this is a very labor-intensive process).
The circles can also be fastened with screws through through holes. If you need a small pulley or have thick plywood, then the pulley can be made from one circle by cutting it out with a jigsaw, putting it on a screw and making a groove by applying a narrow file to the circle rotating on a drill.
Using this principle, you can make pulleys from other materials, for example, from PCB.

The pulley is one of the most important spare parts for both drilling and lathe machines. It is a part whose purpose is to regulate the speed and power of the engine. Of course, factory pulleys have high degree reliability and are designed for your machine, to which they fit perfectly.

But over time, the pulley, like many other parts, fails and requires replacement. In this article we will tell you how to make a pulley with your own hands. A high-quality hand-made part may not be inferior in reliability to factory-made analogues.

There are several views on making pulleys for machine tools at home. Most of the debate is about the material from which this part should be made. Experts say that making a pulley out of wood is a bad idea. The fact is that during operation of the machine, the pulley experiences quite serious thermal and physical activity. Wooden detail It won't work for very long in such conditions.

Pulleys made of metal perform best in the harsh conditions of everyday work, but their manufacture requires special equipment and high lathe skills. Average in quality and complexity of creation (compared to metal and wood) is a homemade product made from plywood. This part can be used both when repairing a factory machine and in the process of creating your own machine.

Homemade plywood pulley

A pulley for any machine can be made without the involvement of a turner. To do this, we recommend taking a plywood sheet with a thickness of about 10 millimeters and following the following instructions:

1. We mark the surface of the plywood in accordance with the planned dimensions of our part. It is worth noting that these parameters must be taken into account when choosing a sheet of plywood.
2. We cut circles from our material. We recommend using a jigsaw for this. During the work special attention Pay attention to the quality of the cuts and the integrity of the workpieces.
3. Considering the thickness of our plywood (1 cm), we cut out 6 circles from it.
4. Take three cut circles and use a drill to drill holes in their center. Their dimensions must be compared with the diameter of the motor shaft of our machine. The holes should be drilled so that their diameter is 1-2 millimeters less than its diameter.
5. We connect three circles with holes using glue and self-tapping screws, which we drill along the edges of the blanks.
6. We expand the hole of the part we created using a round file to such an extent that the workpiece fits tightly onto the motor shaft.
7. We also put three plywood circles without holes on glue and connect them using self-tapping screws. After these circles are securely fastened to each other, we attach them to the main shaft using longer screws.
8. Six fastened plywood circles need to be turned. This is best done with a chisel or file. When performing this work, you must remember that the quality of turning will directly affect the functioning of the homemade pulley.

It is worth noting that in the same way you can make not only a drive pulley, but also a flange for sandpaper and other types of nozzles. In addition, during self-made pulley, it is necessary to take into account the type of belt drive that will be used on the machine. If the transmission is geared, then the pulley should also be made geared. Forming such a part will take much more time, because you will also have to make teeth on the workpiece.

Video: how to make a pulley?

Making an aluminum part

Making a metal pulley is more difficult than its plywood counterpart, but the reliability of such a part will be much higher. We provide detailed step by step instructions for the production of aluminum pulleys. To produce this part, we need a piece of aluminum and a device for melting it down.

• We prepare a mold from polystyrene foam. Before you do this, decide on the required dimensions for your pulley.
• We insert the mold into the sand so that the top piece is not covered with it.
• We smelt aluminum. It is best to do this in a special melting furnace.
• Molten aluminum is poured into the mold.
• We mount the faceplate and the smelted part. To do this, you need to drill holes in the workpiece and fasten the elements using self-tapping screws.
• We grind our detail. This can be done using a grinder.
• We make a hole in our pulley with a drill.

It should be noted that making a metal pulley requires certain skills and resources. For him self-production you will have to spend a lot more time and energy, but such costs will be recouped by the long service life of such a part. Before smelting, you must also make sure that your aluminum has sufficient strength and is suitable for its intended function.

Probably every master of his craft has a tool that is often needed in his work, for example, a file, but sometimes it happens that the handle is not mute or not satisfactory or is completely missing, and at this moment it is necessary to make such a handle in order to return the file to its functionality, A wood lathe is ideal for this, the assembly of which I will talk about in this article. This machine is designed for processing wooden blanks, namely bodies of rotation, with its help you can make various pens, legs, figurines for all sorts of homemade products.

I suggest you watch the video, where I also talked in detail about assembling the machine.

In order to make a lathe you will need:
* Electric drill
* Oak parquet
* Aluminum profiles
* Screws
* Screwdriver
* Electric motor from sewing machine
* Bicycle camera
* Epoxy glue
* Drills
* Hacksaw for metal
* Bearings
* Metal corner

That's all you need to assemble a lathe with your own hands, the materials seem to me to be quite easily accessible, the hardest thing for me was finding the engine.

Let's start assembling the machine.

Step one.
In order to understand what the machine will look like and already imagine the future dimensions, it is necessary to make a frame from four parquet floors, which will be the frame - the main part, it is better to start with it, since all other parts will be attached to the bed. All four parquet floors must be pre-drilled, and then screws must be screwed into these holes, forming a rectangle.

I glued plywood to the bottom to collect the shavings, so that at the end of the work I could easily release this compartment for the shavings by turning the machine over. To prevent the machine from slipping during operation, I screwed on rubber feet.

Step two.
Since any lathe has a tailstock, in my case there will be one too, so in order for it to be secured to the bed, two aluminum corner, which need to be adjusted to length and then drill four holes in each guide and screw them with screws to the parquet flooring on the frame. Before screwing the screws into the frame, you need to drill holes with a drill 1-2mm smaller than the screw, this is done to prevent cracks from forming.

Step three.
It's time to make the tailstock itself. We cut a piece out of parquet and make a groove for the guides. After this, you need to press or glue two nuts along the edges of our future tailstock. The wings will be screwed into these nuts and with the help of this the tailstock will be fixed in a stationary position. To prevent the nuts from being pulled outward when tightened tightly, you need to coat them on top. epoxy glue.

Step four.
While the epoxy glue dries, we make fastenings for the bearings on the headstock. I also decided to make them from parquet, we drill holes for the bearings and press them into their rightful place, for reliability you can coat them seat epoxy resin.

I made the fastenings in the form of an isosceles trapezoid. We also make the base on which the fasteners with bearings will be held from parquet, drill four holes in it and screw in the previously made fasteners with bearings, having previously installed them strictly in the middle.

Step five.
Since in my machine I decided to use a belt drive, I needed to make a pulley on the front headstock and on the motor shaft itself, I took the ratio 1 to 2 to reduce the number of revolutions but increase the torque. The pulley can be made using a drill, installing a piece of wood into the drill chuck through a pin and sharpening it with a cutter or a regular chisel.

Then we screw the pulley onto the pin and install it into the bearings using washers. Also don't forget to lubricate the bearings.

Step six.
We install the headstock and belt on the bed, to do this we drill holes for the screws and tighten everything thoroughly.

After checking the reliability of the rear bearing, I decided that I needed to slightly strengthen the structure with a thin board and epoxy.

Step seven.
Now you need to secure the engine, and it will be mounted on a special mount, which I screwed with an angle to the end of the frame, and also made a movable platform for the engine, which will allow you to adjust the belt tension, which will prevent it from slipping.

Step eight.
After the engine is installed, we make a headstock that will hold the workpiece and transmit torque from the engine to it. The easiest way to do this is to install a square of parquet on the axis of the headstock and grind it with a chisel until round shape, then drill holes in three places and glue three pins sharpened to a cone with epoxy glue. After hardening, you can fix it with a nut and a washer.

Step nine.
My motor is from a sewing machine with a pedal that regulates the speed, it follows that it is not intended for such loads, so I decided to install a fan on the motor shaft so that its windings do not overheat, I think such manipulations will prolong its life.

There were also some modifications; the belt on the pulley slipped while turning the round platform for the trident, so I glued it to both pulleys bicycle camera using "Moment" glue.

Step ten.
What kind of machine is it if there is no tailstock? Let's fix this. The tailstock is assembled from two parquet floors, two bearings and an axle, which must be sharpened to a cone. We place the axle in two bearings, after which we glue them with epoxy into the grooves on the parquet flooring, which will be the tailstock mounts.

When the epoxy has hardened, using screws we attach the resulting structure to the moving part with wings, which I made earlier.