Getting at a pulley

[PastorPaul]

Just as I was making the last few cuts on some ash for my daughter's chess box, my old Craftsman table saw got noisy. I traced it to the pulley moving out on the arbor shaft, causing the belt to be seriously out of line.

I removed the set screw from the pulley, and the key is missing, but I can't get the pulley to move. I'm trying to get it completely off, so I can get a new key for it. Is there an easy way, in such a confined space, to get that pulley to work loose?

Pastor Paul

[Chris Moore]

Paul,
About the only way to get that pulley off without warping it or damaging the shaft is with a wheel puller. Harbor Freight has some serviceable ones on sale cheap. Then next bet would be to stop by you local (non chain) auto parts dealer. More than likely they'll lend you one long enough to get the pulley off. They'll also have the right sized key stock.

Chris Moore
Montgomery, AL

"... and remember, there is no more important safety rule than to wear these - safety glasses."

[Bob Hobbs]

I had the same thing happen to me and I saw it for a revelation. A voice spoke to me and said, "Beateth that pulley off and if it breaks, it needed replacing anyway, and then go to Woodcraft Supply and searcheth on Contractor Saw Upgrade Kits and if thou already hast a link belt, calleth the 1-800 number and ask if you can get the pulleys only." And I did and did rejoiceth in the further reduction of noise and vibration.

I used a pry bar and a dead-blow mallet and a long piece of 1x2 oak.

(Hartville Tool www.hartvilletool.com has the same deal -- search on "pulley" for a few dollars less.)

[Lou_williams]

Bob is right on this one. The standard pulley from Crapsman is one of the worst ever made. If you don't have the link belt get that too. With the new pulleys and belt you will have a new saw. Or at least think you do.

When the same thing happened to be I cut a hole in the side of the sheet metal side of the saw to get at the pulley. I wanted to always be able to get at it.

[Robert M]

Many "moons" ago, my first TS was a Craftsman and I had the same problem you've described. After you find/borrow/buy a gear puller and remove the pulley and replace the key, I'd like to suggest that you use TWO set screws. That simple addition ended the problem, once and for all.

[PastorPaul]

OK, guys, read my post again. There is no room to work in there. No room for a pulley or gear puller. Not really much room to "beateth" the pulley off or to pieces. Next idea?

Pastor Paul

[Chris Moore]

Many moons ago I had a VW Type 181 (The Thing). Well when the front wheel bearings went bad on my schoolbus yellow Thing, the inner races siezed to the spindles. I had to use an acetelyne torch to cut through the race down to the spindle. Since the spindle was much harder than the bearing race the torch didn't damage the spindle. A couple of easy whacks with a hammer and a long chisel broke the race right off leaving a nice shiny undamaged spindle. This technique might work in your situation.


Chris Moore
Montgomery, AL

"... and remember, there is no more important safety rule than to wear these - safety glasses."

[Bob Hobbs]

Lou cut a hole in the sheet metal side of the saw.

I used a metal pry-bar kind of like a cats-paw nail puller. I got one end between the pulley and shaft housing(?) and beat on the other end and pried that pulley off. And it didn't come easily or willing. I sat on an upended milk crate and banged away and then turned the blade and banged away and then turned the blade and banged away and eventually it came off. I may have wedged some wood in there to get better leverage, but it *will* come off.

If you're constrained to replacing the key, and can't find the one from the blade pulley, you can take your motor pulley off and carry that key down to your local True Value and in their nuts and bolts collection they will have shaft keys.

[Robert M]

I remember that turning the entire saw upside down helped me access the arbor shaft, but it's been 25 years or so and I've taken a nap or two since then. Once, I had to take the leg assembly completely off and I wonder if the arbor shaft pulley was the reason. (I honestly don't remember. I guess it's true, the first thing to "go" really IS your memory.)

As far as gear pullers are concerned, they come in many sizes and configurations. The one I used on the Craftsman (this I do remember) is a specialty tool manufactured for the oil industry.

[Jerry Semi]

Paul,
You may well have a burred shaft, try pushing the pulley towards the bearing and buffing the shaft with emery cloth.
I'm in Camdenton, if you bring the saw here I know we could get it off.