DC Motor shaft

[wjfiles]

Hi All,
I have a DC motor with a hardened shaft that has a helical gear machined into the shaft. I takes up almost all the protruding shaft. 3/8 diam.
Are there any sneaky ways to adapt a pulley 1" diam, to this shaft.
If there is a way I intend using it for a spindle drive on my router to cut down the noise.
Thanks in advance
wjf

[Al_The_Man]

You could fill the gear up with one of the metallic epoxies and turn it down, But I assume you have Universal motor right now? hence the noise?
The only problem you may run into with the DC motor is rpm limit unless the motor is large enough to gear up, as DC Motors traditionally are fairly low rpm, 2000 ~ 3000 max, for router applications.
Al.

[Andre' B]

Assuming that the OD of the gear is the same size or smaller then the motor shaft you can't grind off the gear teeth and have enough diameter left to do anything.

Make a pulley out of AL so the bore is a heavy press fit (say 0.005 to 0.008 interference) on the OD of the gear. With the motor spinning grind a small leading angle on the teeth at the end of the shaft so that when you press it on the gear does not broach groves in the pulley.

When pressing push on the pulley and the opposite end of the motor shaft not the motor housing or you may damage the motor bearings. And if it is pressing too hard open up the ID of the pulley a bit to avoid bending the motor shaft. At this point it is a feels about right kind of thing.