Best way to mount pulley and handle on knee drive

[brian257]

I have been trying to come up with some kind of elegant way to mount the knee drive pulley on the shaft of my Bridgeport while retaining use of the manual crank handle and the original dial. I have attached a picture of the parts for reference. As we all know the wheel dial and locking knurled nut normally go on first then the drive coupling splined piece (whatever it is called) slides on the shaft and engages with the key on the shaft under the part that the dial goes on and the handle goes on the remaining part of the protruding shaft. Obviously there is no shaft left over for the pulley.

What I am trying to accomplish is that I need the pulley mounted on fairly close to the bottom of the stack then I want to be able to retain the original dial and locking mechanism and handle. What methods have other people used to stack all these parts up and make it work? Can this be accomplished without having to make a new longer shaft?

All I know for sure so far is that I will have to machine off the hub of the pulley to get the thickness down some.

[txcncman]

Build a coupler/adapter/step shaft to move everything out front of the pulley.

[brian257]

Now that I have done a little more research and figured out how to remove the dial holder (http://www.cnczone.com/forums/bridge...rt_mill_-.html) and looked at how some of the Z axis power feeds go on I am thinking the thing to do might be to just make a new bigger shaft to slide over the old one then I can put a keyway in the inside of the new shaft to lock it to the old one, bore out the old dial holder and key it so it slides over the new larger shaft, and make a new handle and clutch mechanism or maybe even I could bore out the old ones for the new larger shaft.

I would still like to see how others have done this.

[txcncman]

Basically that is what I was saying to do.