Today's Message Index:
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1. 06:12 AM - Re: Reducing a hole diameter? (alternator pulley) (FLYaDIVE)
2. 06:24 AM - Re: Re: Reducing a hole diameter? (alternator pulley) (FLYaDIVE)
3. 06:27 AM - Re: First Flight N601T (Larry McFarland)
4. 06:31 AM - Re: [Probable Spam] Re: Reducing a hole diameter? (alternator pulley) (Larry McFarland)
Message 1
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| Subject: | Re: Reducing a hole diameter? (alternator pulley) |
Michel:
I would just ask them to MASK the keyway. In the business it is know as
DOUBLE MASKING one layer of special masking tape and a coating of a liquid
masking over the tape.
The cost for masking might be $30 tops ... It is the labor you are paying
for.
It sure would be much less time consuming than re-cutting AND ... HERE is
the BIG AND ...
Hard Coat Anodize can have a theoretical Rockwell of over 60. This makes it
VERY difficult to machine AND even if you did machine it, so hard it can
dull a carbide bit. Also penetration part of the hardcoat after machining
never is smooth. Go with the masking.
Barry
On Mon, Mar 8, 2010 at 5:40 PM, Michel Therrien <mtherr@yahoo.com> wrote:
>
> Thanks for the response... The material is 6061-T6.
>
> The pulley is the one going on the engine side, not the alternator side.
>
> If I get the part anodized, I could recut the key hole after (?)
>
> ----------------------------
> Michel Therrien CH601-HD, C-GZGQ
> http://mthobby.pcperfect.com/ch601
> http://pages.infinit.net/mthobby
>
>
> --- On Mon, 3/8/10, FLYaDIVE <flyadive@gmail.com> wrote:
>
> > From: FLYaDIVE <flyadive@gmail.com>
> > Subject: Re: Zenith-List: Reducing a hole diameter? (alternator pulley)
> > To: zenith-list@matronics.com
> > Received: Monday, March 8, 2010, 4:47 PM
> > Plasma coating is NOT the way to go.
> > There are so many things to wrong with that process:
> > 1 - It is a hand operation - In this case
> > 2 - It is inside a through hole - Very difficult to
> > get a uniform coating
> > 3 - It is OPERATOR dependent
> > 4 - HEAT is going to be high on the issue list - Again
> > operator dependent
> > 5 - The part has to be VERY roughly sand blasted 20 to
> > 40 grit - And there is a sharp edge that won't be any
> > more ... More machining.
> >
> > The idea of using Hard Coat Anodizing is a good one.
> > But the build up is NOT 100% build up.
> > Example: a coating of 0.002" is ONLY a build up
> > of 0.001" and a penetration of 0.001". The
> > coating shop calls that a 0.002" Coating. IF - The
> > hole dimension is off by 0.003" you will need a build
> > up of 0.0015" per side so that means a coating of
> > 0.003"
> >
> > THAT is difficult to do on many aluminum's,
> > especially 2024. I don't recall, what was the sheave
> > was made from?
> > AND don't forget - - - They will have to mask the
> > key-way. Masking is the costly part of the job. The rest
> > of the part could be coated.
> >
> > Shimming will NOT cause the the sheave to go off
> > balance. If that was the case the Woodruff Key would cause
> > it to go off balance. Also the weight distribution is so
> > close to the centripetal center that a much larger mass
> > would be need to cause an out of balance condition. BUT!
> > If you have the opportunity to do so... BALANCE the
> > alternator rotor and still if you have the equipment... Do
> > it in the housing.
>
>
> __________________________________________________________________
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>
>
Message 2
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| Subject: | Re: Reducing a hole diameter? (alternator pulley) |
You are correct Michel:
The only thing I can think of that would work against you and it works
against all of us is VIBRATION and maybe a back-fire.
Barry
On Mon, Mar 8, 2010 at 6:18 PM, Michel Therrien <mtherr@yahoo.com> wrote:
>
> Well. this is exactly what I thought about and I did not readilly see
> consequences... the pulley will be attached very tightly to the shaft using
> a 1/2" lock nut and washer (it is not just pressed fit.. It has a woodruf
> key and if the materials wears out (which I don't know how it would do that
> since there is no relative movement), the most the pulley will move is
> .002". All the material around the hole is thick, and solid. I'm no
> expert... could it cause the lock nut to unscrew itself?
>
>
> ----------------------------
> Michel Therrien CH601-HD, C-GZGQ
> http://mthobby.pcperfect.com/ch601
> http://pages.infinit.net/mthobby
>
>
> --- On Mon, 3/8/10, ronlee <rlee468@comcast.net> wrote:
> > Consider the consequences if it should fail. After all this
> > isn't going on a garden tractor!
> >
> > --------
> > Ron Lee
> > Tucson, Arizona
> do not archive
>
>
> __________________________________________________________________
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>
Message 3
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| Subject: | Re: First Flight N601T |
Congratulations Jeff! Major accomplishment.
Your adventure has just begun.
Do fly safe,
Larry McFarland 601HDS at www.macsmachine.com
Do not archive
Jeff wrote:
>
> WARRENTON, Virginia - Today Sunday March 7, 2010 another homebuilt
> aircraft took to the skies. Test pilot Bob Garity took Zenair Zodiac
> N601T up for its first flight. This CH601-HD two-seat aircraft was
> built by local pilot and builder Jeff Davidson. Mr. Davidson headed
> up a ground crew of local pilots. The ground crew was ready on foot,
> bicycle, and motorized vehicles. Mr. Garity reported that all
> systems worked well and that the plane flew with no bad
> characteristics. The only squawk concerned the volume of the
> communications radio during transmissions. A previous attempt
> occurred on Friday March 5th. That attempt ended with a dead
> battery. Charged up and pre-heated today the plane started easily.
> Pilot Garity indicated that starting the engine with the throttle at
> idle helped start it easily. With this technique, the engine started
> in just 2-3 blades. Once airborne several touch and goes were
> performed. With a busy pattern, at least two go-arounds were
> performed. Acceleration on take off was reported to be excellent and
> landings were characterized as easy with no bad characteristics on the
> ground. The test flight was conducted entirely in the Warrenton (HWY)
> traffic pattern. Some pictures are attached. Builder Davidson
> reported that the second flight will follow in short order.
>
> *
>
> *
Message 4
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| Subject: | Re: Reducing a hole diameter? (alternator |
pulley)
Michel,
After a bit of thought, aluminum wouldn't be a good choice for a core
replacement. I'd suggest
you make a small steel hat-sectioned insert to center it with hole and
key and rivet the small
thin flange in place. Then the pulley would have better strength than
the original.
Larry McFarland 601HDS at www.macsmachine.com
Michel Therrien wrote:
>
> Thanks for the response... The material is 6061-T6.
>
> The pulley is the one going on the engine side, not the alternator side.
>
> If I get the part anodized, I could recut the key hole after (?)
>
> ----------------------------
> Michel Therrien CH601-HD, C-GZGQ
> http://mthobby.pcperfect.com/ch601
> http://pages.infinit.net/mthobby
>
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