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Making Pulley Wheels from Plastic (Read 1,187 times)
 
Mike Turner
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Making Pulley Wheels from Plastic
Aug 31st, 2016 at 7:13pm
 
I have picked up a router crafter and need to make a replacement plastic 2 1/4" pulley...I saw a link where a guy took a hole saw and cut 3 plastic disks.One was a little smaller than the other 2. He used a drill bit with a 1/4" bit.He sandwiched the small disk between the 2 larger ones and pop riveted the 3 together.I need to know where I can find some 1/8 or so plastic and what is the best kind or right type of plastic?
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Dwight Rutherford
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Re: Making Pulley Wheels from Plastic
Reply #1 - Aug 31st, 2016 at 10:40pm
 
If you have a "Tab Plastics" locally, or if not "Amazon". Lexan would probably be best.
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Ed Weber
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Re: Making Pulley Wheels from Plastic
Reply #2 - Sep 1st, 2016 at 9:15am
 
Mike Turner wrote on Aug 31st, 2016 at 7:13pm:
I have picked up a router crafter and need to make a replacement plastic 2 1/4" pulley


Okay, I'll say it, why don't you just turn one.
The pulley doesn't need to be balanced or withstand  high speeds, it just has to be the correct diameter and round. Hardwood or even UHMW plastic (available at woodworking stores) would work fine, there really isn't (shouldn't be) an excessive amount of stress on it. The lamination method you mentioned would most likely be stronger but it may be overkill for this application.
JMO
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Walt Nollan
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Re: Making Pulley Wheels from Plastic
Reply #3 - Sep 1st, 2016 at 11:00am
 
I agree with Ed, as much as that hurts, mine broke maybe 18 years ago so I made one out of wood.  It works!
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Mike Turner
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Re: Making Pulley Wheels from Plastic
Reply #4 - Sep 1st, 2016 at 4:21pm
 
I think Ill make one from wood!!!  Thks!
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Bert Delisle
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Re: Making Pulley Wheels from Plastic
Reply #5 - Sep 1st, 2016 at 9:23pm
 
You could make one out of HDPE, cut up some milk bottles, shampoo bottles, mustard containers, anything that has the recycle #2 HDPE logo on it. Cut up into small pieces and put in  tomato can, heat to 375F, the plastic will be like chewing Gum, pack the can contents tightly. I turned a disk that just fit the can and used my bench vide to apply pressure. Once it cools mount in a chuck and turn the pulley to your spec.
It works great, cuts like butter and is very dense and strong.
Or you could just make one from hardwood. Smiley
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Mike Turner
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Re: Making Pulley Wheels from Plastic
Reply #6 - Sep 2nd, 2016 at 2:58am
 
Bert Ill have to remember that one....!!
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Dirk Hoogendoorn
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Re: Making Pulley Wheels from Plastic
Reply #7 - Oct 8th, 2016 at 12:26pm
 
Bert Delisle wrote on Sep 1st, 2016 at 9:23pm:
You could make one out of HDPE, cut up some milk bottles, shampoo bottles, mustard containers, anything that has the recycle #2 HDPE logo on it. Cut up into small pieces and put in  tomato can, heat to 375F, the plastic will be like chewing Gum, pack the can contents tightly. I turned a disk that just fit the can and used my bench vide to apply pressure. Once it cools mount in a chuck and turn the pulley to your spec.
It works great, cuts like butter and is very dense and strong.
Or you could just make one from hardwood. Smiley


Gee Bert great answer, now why didn't I think of that?
That is the typical Dutchmen reply.
Why do Dutch guys have flat forheads and hunched shoulders?---Answer: You as them a question and the just hunch their shoulders, when you tell em the answer they slap their hand against their forehead and exclaim "why didn't I think of that"  Wink
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