GT-ER

If anyone has the bad luck I've had and has had their pulleys come off...this may be your solution.

This is what it looked like when my pulley came off....you can see the stock key sheered off:



This is what I did now:




I used my dremel with a tungsten carbide bit to make a canal and installed a parallel style key. The key is not only twice as long as the oem key...it's also about twice as think in the end points ( woodruffs are half moon shaped, this one is just rectangular ). It looks like it protrudes in the picture, but it doesn't...it's flush with the tip on the crankshaft.

As soon as I get a new bolt and seal...it's time to bolt on the damper AGAIN and see how this new key holds up. I honestly can't see this failing but I guess we'll find out eh?

Vic55

I dont know--- Im no expert but all this cant be as good as stock. Didnt the factory design it to be optimal?

Let the gamble continue.

GT-ER

I'm not recommending this for anyone who's oem setup is working just fine...I'm at the point where it's either this or a new crankshaft or engine cause my snout is pretty banged up. If I were to install a new crankshaft then I would install the oem key instead of this.

At this moment I just need something that's pretty bulletproof...and this will hopefully be just that.

GT-ER

This is where I got the idea from:

http://www.crossfireforum.org/forum/...-survived.html

Thanks velociabstract.

benz_addict

Looks good man, clean smart work. I hope it holds up. Keep us posted on how it works out.

Velociabstract

You work fast! I've got my fingers crossed for your success. Especially if it quiets down ole what's his name. Long live DIY.

Les

I want to line up with you one of these days, even though I may not stand a chance. Next rental? Looser buys the beers. Medalla or Curs.

GT-ER

Thanks guys...it was actually quicker than I expected. I didn't have to remove the timing cover for this and the tungsten carbide bit really ate the crankshaft up pretty quick. I put about 1 hour of labor into this.

wsybert

Nice work. I read the other forum thread... impact wrench!?! That's knowing how to "git-R-done".
If your key is snug in the slot and the pulley, and you get the required torque... I'm betting it works.
Bill

FASN8N

Fingers crossed for you buddy!

Velociabstract

You may want to check all the pulleys while the belt is off. It's possible one is bad and putting a lot of stress on the crank pulley. Just thinking out loud. You still don't know for sure why the key didn't hold. Check them just in case before you get it all assembled.

Les

320 dreamer

any way to clean up that crank end? it looks pretty scarred up and that cant be good for the next pulley

novae500

i hope this mod will help out and keep the pulley on this time!

GT-ER

The key is VERY snug. The required torque shouldn't be a problem with my new wrench.

Thanks!

Did that while I took a small break. They are all good. Especially my ASP Idler pulley.

I fear that any more "cleaning" will only make the snout thinner and it'll have even less grip when bolted on. It got scarred up pretty bad and I think it's the reason why it didn't hold on round 2.

Usually parallel style keys are used with pulleys that are completely loose ( where the key is solely responsible for making the pulley turn, or the pulley making the shaft turn ) so it really shouldn't fail.

Trust me...I hope so more than you do.

Hotrod-Realtor

Looks good to me. I have had a couple of superchargers on boat motors. It was common to cut an additional key way in the crank to have two keys instead of just one.
Question to the rest of you. Isn't the key and the clamping force of the bolt head to the pulley the only two things keeping the pulley from spinning on the crank?

Hellzno

looks good....good luck.

GT-ER

Yup.

In my case since the clamping force is expected to be less due to the damage, I'm hoping that having a key twice as strong will do the trick.

AKnight55

For once I can actually say Im glad I have a stock pulley..

KLR CLS

Good job man. I bet it does the trick. Way to tackle it head on!

400RWHP

Noticed there is oil laying at the bottom of the timing cover and timing chain is covered in oil, I am wondering where the oil seal is? I haven't had to tear down one of these engines, but on other cars I've owned the keyway was towards the engine side of the crank because a rubber main oil seal went over the crank and was held in place by the pulley. Is that not the case on these engines? I'm asking because your keyway goes all the way to the end of the crank(looks fantastic by the way), just wanting to make sure it isn't going to interfere with an oil seal that slips over the crank.

In any event, way to keep going man, I would have had a breakdown by now, so I applaud your tenacity. Please keep us posted.

Regards

Viet_Amg408

what about all those aluminium shaving?

Jakpro1

Haven't read through all the replys so forgive if am doubling. Doesn't this scream balancing issues bro? I dunno, maybe it's nothing but you've just added a weight to a perfectly balanced crank system. You have been through so much, please let it work for ya!!

KLR CLS

Guys this is done all the time on cars with aftermarket SC kits. Vipers, Vettes, even porsches I don't think could have come up with a better solution. Either a parallel key or roll pin is just fine

GT-ER

I had to take the seal off to make room for me to do this. Now I need a new seal. The seal will not interfere.

I shoved a microfiber towel inside where the oil pump chain is. I doubt any shavings fell into the oil at all. I'm going to be replacing the oil anyways and IF there were to be any shaving that I miss, the oil filter should pick it up without issues. I've done worse....lol.

Shouldn't matter. It's close to the centerline of the crankshaft and whatever material I removed, I replaced with the key. Keep in mind, the factory crank is balanced WITHOUT the woodruff key installed.

AWOL

too sketchy for my blood

guysandiego

I am concerned about the key being tall enough -- hard to tell from the pictures -- but looks as if the OEM key was half the length but twice as tall as the one you put in ... If thats the case -- You better make that new key taller.... other wise it looks great - good luck