Exup pulley

[stevierst]

Some of you might know that I recently snapped my exup pulley wheel trying to service my seized valve.

As I can't source one for love, nor money, and being a former engineer, I thought I'd make one myself!

I found some steel plate in my "workshop" and set to work cutting out 3 plates I intended on rivetting together.

That's the main one done.
This next one is for the centre of the pulley where the cable lies.

And the backplate.
I clamped them all together and drilled the rivet holes.

I pinned the lot together, and riveted it up.




Just needs dressing up.


And here it is fitted to the exup cables ready for the valve to go back in.


Backyard engineering at its best!

[Falcon 269]

You bet!  Nice work - like it.

[slimwilly]

Very good,,have a "Gold star"

[steeeve66]

Genius!

[woodwizzard]

Good work, 8 out of 10, dropped a couple of points for not using titanium 

[savvy]

Damn Steve you put some work in!!
 Well done there!!!!

[robin78842]

Man after my own heart!!

[stevierst]

Just finished bolting the beast back together.


Took her out for a test ride, and she works beautifully again, the R1 has its teeth back!

[mickvp]

looks cracking, love it

[dickturpin]

Could be the start of a production line....

[fireblake]

Could be the start of a production line....

That's what I was thinking. How much time did you invest in it? What costs were involved and how easy would it be to knock up another if needed?
Just curious, mine broke but I managed to source another.


Mickey

[stevierst]

It was about 4-5 hours of cutting, drilling and filing.
Now I know what I'm doing, should take 1/2 that.
Materials are 3mm steel plate for the big  plate, and 2mm plate for the other two. Plus a couple of 2mm nails as the rivets.

I'd need an exup valve (broken or knackered) to fit the oval mounting hole to though, as this is the important bit if I was to make another.

[b1k3rdude]

Now that's proper engineering, that is 

If these could be made cheaply enough from stainless steel (mild steel will rust away in that location), it would be a worthy replacement. Instead of all that filling and hacksawing, laser cutting springs to mind. Do you still have all the templates to hand..?

Also how did you secure the nails you used to join the 3 pieces together, burred over the end with a drift or ballpeen hammer..?

On a random note, I wonder if there is a hi-temp heat resistant material that could be 3D printed for something like this..?

[stevierst]

The template was the broken pulley, and I took measurements off it with a vernier caliper.
It could be made in two parts easily enough with a lathe and laser cutter in about an hour, then riveted together at the assembly stage.
The hardest part was getting it to all line up with the valve shaft as its flat sided.
And as for the rivets, yep, a good old ball pein hammer, drifts and patience!

If I had all my old machinery, I could have knocked a few of these out with ease.

[boorat]

http://www.cmsnl.com/yamaha-fzs1000nnc-2001_model10898/pulley_2tk1486501/#.U-iaxIFwbqA

[stevierst]

Good find boorat! €33 too. Cheap at 1/2 the price.

[boorat]

I had the same problem as you and yamaha wanted 3 legs and 2 arms for it.. thats a top job youve done by the way

[robin78842]

Cheap at 1/2 the price.
[/size]
[/size]
[/size]I think the saying should be "Cheap at TWICE the price".

[stevierst]

Cheap at 1/2 the price.
[/size]
[/size]
[/size]I think the saying should be "Cheap at TWICE the price".

I was taking the Piss!

[fireblake]

Cheap at 1/2 the price.

Thanks Steve, my dear old Dad used to say that about most things. That put a massive smile on my face


Mickey

[brooker81]

Good work Ste you can fit my headers for me when they arrive.

[stevierst]

I'll gladly fit them bud, giza shout when they get here. :P