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Old 05-08-2010, 05:20 PM   #109
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Originally Posted by Grumpy View Post
Rodger........the front face of the pulley (the bolt/washer seating surface) has to be/should be "proud" (be past the end of the crank). I was just interested.
It is/was proud by about 1.5mm.

Originally Posted by Grumpy View Post
Once you grind the remaining bolt off why don't you just soak the area with penetrating oil, and take an overnight break.
Good idea matey! ~ My own bad idea was to go and get a hole saw for my electric drill and drill a 22mm hole right out the centre, but it wouldn't 'bite' so the bolt must be made of even stronger stuff? Next I tried to drill a circle of small 3mm holes around the end of the bolt shaft with a titanium bit but again it wouldn't even bite, so the bolt metal must be super super toughened? I could not use the heavy duty grinder because the grinding disc diameter is larger then that of the smaller outside pulley [i.e. it wouldn't fit inside to reach the washer surface].

So it was back to the tiny carbide dremel cutting wheel again in order to continue were I left off yesterday. Takes a long time and a lot of patience!! People walking past muttered that I was still 'messing' with that bloody car! Just as the dremel was about to break through the final section it went "BANG!". Changed the fuse and bushes but the thing is dead, I think the strain of the job killed it? Certainly the longest and most strained job my dremel has ever done! ~ R.I.P.

So, I finish it with the good old club hammer and cold chisel. The corrosion WAS bonding the washer to the pulley! But a couple of tiny blows with the club hammer and off it fell.

Originally Posted by Grumpy View Post
Hope the pulley(s) come off easily without having to have you adapt that puller.
Now the washer has gone, the centre hole is a lot bigger, so there was no need to adapt the puller. I put it on and started turning the centre screw of the puller by hand, I was ready to attach the socket and 'half inch drive' wrench but I didn't even need it as I was able to pull the pulleys off just by tightening the puller by HAND!

Originally Posted by Grumpy View Post
If required, have you got a good, small (3/8" or something close), sharp cold chisel or something similar? If there is not enough of the bolt to grab onto, then a sharp tool that will "dig" into or "catch" the end of the bolt so that you can work/rotate the bolt out, may be useful.......if you get my drift.
Yes! ~ I deliberately left a small part of the washer attached to the bolt shaft to act as a lug [lever] SEE PHOTO. I placed the cold chisel against the lug and gave two tiny taps with the club hammer to spin it CCW then I was able to grip it with my finger tips and unscrew it without any resistance at all. I didn't even need to make a groove in it 'like a screw head'!!

Originally Posted by Grumpy View Post
Does the large pulley have elastomer (rubber) damper material that I think I see in your enlarged photos?

...the timing sprocket isn't 'off centre'!! [it's just the camera angle].

So, the next question is: how to get the bent 'locking' pin out of the side of the block?


Last edited by the_doc735; 05-09-2010 at 04:51 PM.
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