Help with JB Weld.

Background: This is on an IH Model 100 sickle bar mower. The drive pulley on the balanced head was broken off from it's center and rewelded by the PO which eventually selfdestructed. Most of the damage was in the pulley, but the shaft has some minor damage basicly elongation of the slotted keyway side to side. I have checked on replacement parts which surprisingly are still available, but lets say the term "cost prohibitive" would be an extreme understatement. So I am looking for the best way (read cheapest/quickest/easiest, you get the idea) to put this thing back together. I have found a good pulley which goes on OK and holds with just hand pressure turning the pulley, but before I put any stress on it I would like to build up the area on the sides of the key slot. I was thinking of using JB Weld but don't want to just goop it up and glue together permanently (the thought of ever having to get it off again is not entertaining). Does anyone know of a release agent like wax paper, grease, ..etc that I could put on the key or maybe between the pulley and shaft so that I could apply the JB Weld to the shaft and then tighten the pieces together to form a mold? Thanks for any ideas, Stan(VA).

: Background: : This is on an IH Model 100 sickle bar mower. The drive pulley on the balanced head : was broken off from it's center and rewelded by the PO which eventually : selfdestructed. Most of the damage was in the pulley, but the shaft has some : minor damage basicly elongation of the slotted keyway side to side. I have : checked on replacement parts which surprisingly are still available, but
: lets say the term "cost prohibitive" would be an extreme understatement. : So I am looking for the best way (read cheapest/quickest/easiest, you get the : idea) to put this thing back together. I have found a good pulley which goes on : OK and holds with just hand pressure turning the pulley, but before I put any : stress on it I would like to build up the area on the sides of the key slot. I : was thinking of using JB Weld but don't want to just goop it up and glue : together permanently (the thought of ever having to get it off again is not : entertaining). Does anyone know of a release agent like wax paper, grease, : ..etc that I could put on the key or maybe between the pulley and shaft so that : I could apply the JB Weld to the shaft and then tighten the pieces together to : form a mold? : Thanks for any ideas, : Stan(VA).

Stan, From experience I think your best choice would be to J-B Weld the key in the shaft (assuming it's a half moon or reg. square key) . You can make certain the key is positioned correctly by applying a small bit of weld under the key and on it's lower sides and then hand install the pulley. Keep the keyway on top and the weld will stay in place. Let it fully cure, and then apply some more weld to the sides of the key that still have a little gap in the shaft. Then install the pulley using Loctite 609. If the pulley still seems loose. Get a center punch and a small hammer and go around the shaft putting in a orderly pattern of dents. This will swell the shaft a little and then the 609 will set up to a good grip. Be sure to have a good driver to put the pulley back into position on the shaft after the buildup. Loctite works good with J-B Weld. Heating the pulley a bit should make it easy to come apart next time.

: Background: : This is on an IH Model 100 sickle bar mower. The drive pulley on the balanced head : was broken off from it's center and rewelded by the PO which eventually : selfdestructed. Most of the damage was in the pulley, but the shaft has some : minor damage basicly elongation of the slotted keyway side to side. I have : checked on replacement parts which surprisingly are still available, but
: lets say the term "cost prohibitive" would be an extreme understatement. : So I am looking for the best way (read cheapest/quickest/easiest, you get the : idea) to put this thing back together. I have found a good pulley which goes on : OK and holds with just hand pressure turning the pulley, but before I put any : stress on it I would like to build up the area on the sides of the key slot. I : was thinking of using JB Weld but don't want to just goop it up and glue : together permanently (the thought of ever having to get it off again is not : entertaining). Does anyone know of a release agent like wax paper, grease, : ..etc that I could put on the key or maybe between the pulley and shaft so that : I could apply the JB Weld to the shaft and then tighten the pieces together to : form a mold? : Thanks for any ideas, : Stan(VA). Stan, will this shaft come off, or is that a MAJOR undertaking? If it will come off, I would fix it right the first time. I would take it to a good welder and have it built up with weld and then machined down for a tight fit on pulley and key. Its probably a moot point if you can't get the shaft off. Good Luck! Gary

: Background: : This is on an IH Model 100 sickle bar mower. The drive pulley on the balanced head : was broken off from it's center and rewelded by the PO which eventually : selfdestructed. Most of the damage was in the pulley, but the shaft has some : minor damage basicly elongation of the slotted keyway side to side. I have : checked on replacement parts which surprisingly are still available, but
: lets say the term "cost prohibitive" would be an extreme understatement. : So I am looking for the best way (read cheapest/quickest/easiest, you get the : idea) to put this thing back together. I have found a good pulley which goes on : OK and holds with just hand pressure turning the pulley, but before I put any : stress on it I would like to build up the area on the sides of the key slot. I : was thinking of using JB Weld but don't want to just goop it up and glue : together permanently (the thought of ever having to get it off again is not : entertaining). Does anyone know of a release agent like wax paper, grease, : ..etc that I could put on the key or maybe between the pulley and shaft so that : I could apply the JB Weld to the shaft and then tighten the pieces together to : form a mold? : Thanks for any ideas, : Stan(VA).

Maybe something like Saran wrap around the key, fill gaps with the J-B ,then dress any excess with a file. Good Luck.

: : Background: : : This is on an IH Model 100 sickle bar mower. The drive pulley on the balanced head : : was broken off from it's center and rewelded by the PO which eventually : : selfdestructed. Most of the damage was in the pulley, but the shaft has some : : minor damage basicly elongation of the slotted keyway side to side. I have : : checked on replacement parts which surprisingly are still available, but
: : lets say the term "cost prohibitive" would be an extreme understatement. : : So I am looking for the best way (read cheapest/quickest/easiest, you get the : : idea) to put this thing back together. I have found a good pulley which goes on : : OK and holds with just hand pressure turning the pulley, but before I put any : : stress on it I would like to build up the area on the sides of the key slot. I : : was thinking of using JB Weld but don't want to just goop it up and glue : : together permanently (the thought of ever having to get it off again is not : : entertaining). Does anyone know of a release agent like wax paper, grease, : : ..etc that I could put on the key or maybe between the pulley and shaft so that : : I could apply the JB Weld to the shaft and then tighten the pieces together to : : form a mold? : : Thanks for any ideas, : : Stan(VA).

: Maybe something like Saran wrap around the key, fill gaps with the J-B ,then dress any excess with a file. Good Luck.

: How about this: Coat the splined shaft with some type of release agent, ie. spray paint or vaseline, and set in a mold of plaster of paris. Remove when set by tapping out, then use this new mold to cast an input shaft out of some more plaster of paris, or a rubber compound. Use this plaster or rubber input shaft to create the keyway with JB Weld in the original piece. When it is set, chip out plaster shaft, or burn or melt out rubber one (if it does not come easily). Then, use original shaft in the new keyway. May be too much work, but look on it as an adventure in frugality. John.

: : : Background: : : : This is on an IH Model 100 sickle bar mower. The drive pulley on the balanced head : : : was broken off from it's center and rewelded by the PO which eventually : : : selfdestructed. Most of the damage was in the pulley, but the shaft has some : : : minor damage basicly elongation of the slotted keyway side to side. I have : : : checked on replacement parts which surprisingly are still available, but
: : : lets say the term "cost prohibitive" would be an extreme understatement. : : : So I am looking for the best way (read cheapest/quickest/easiest, you get the : : : idea) to put this thing back together. I have found a good pulley which goes on : : : OK and holds with just hand pressure turning the pulley, but before I put any : : : stress on it I would like to build up the area on the sides of the key slot. I : : : was thinking of using JB Weld but don't want to just goop it up and glue : : : together permanently (the thought of ever having to get it off again is not : : : entertaining). Does anyone know of a release agent like wax paper, grease, : : : ..etc that I could put on the key or maybe between the pulley and shaft so that : : : I could apply the JB Weld to the shaft and then tighten the pieces together to : : : form a mold? : : : Thanks for any ideas, : : : Stan(VA).

: : Maybe something like Saran wrap around the key, fill gaps with the J-B ,then dress any excess with a file. Good Luck.

: : How about this: Coat the splined shaft with some type of release agent, ie. spray paint or vaseline, and set in a mold of plaster of paris. Remove when set by tapping out, then use this new mold to cast an input shaft out of some more plaster of paris, or a rubber compound. Use this plaster or rubber input shaft to create the keyway with JB Weld in the original piece. When it is set, chip out plaster shaft, or burn or melt out rubber one (if it does not come easily). Then, use original shaft in the new keyway. May be too much work, but look on it as an adventure in frugality. John.

Thanks for the input guys. I thought about welding, but pulling that ballanced head assy apart looks like a pain in the neck (and the wallet). Under the circumstances I think the saran wrap approach will be the most reasonable. But John, you certainly get honorable mention for originality!
Stan.

: : : : Background: : : : : This is on an IH Model 100 sickle bar mower. The drive pulley on the balanced head : : : : was broken off from it's center and rewelded by the PO which eventually : : : : selfdestructed. Most of the damage was in the pulley, but the shaft has some : : : : minor damage basicly elongation of the slotted keyway side to side. I have : : : : checked on replacement parts which surprisingly are still available, but
: : : : lets say the term "cost prohibitive" would be an extreme understatement. : : : : So I am looking for the best way (read cheapest/quickest/easiest, you get the : : : : idea) to put this thing back together. I have found a good pulley which goes on : : : : OK and holds with just hand pressure turning the pulley, but before I put any : : : : stress on it I would like to build up the area on the sides of the key slot. I : : : : was thinking of using JB Weld but don't want to just goop it up and glue : : : : together permanently (the thought of ever having to get it off again is not : : : : entertaining). Does anyone know of a release agent like wax paper, grease, : : : : ..etc that I could put on the key or maybe between the pulley and shaft so that : : : : I could apply the JB Weld to the shaft and then tighten the pieces together to : : : : form a mold? : : : : Thanks for any ideas, : : : : Stan(VA).

: : : Maybe something like Saran wrap around the key, fill gaps with the J-B ,then dress any excess with a file. Good Luck.

: : : How about this: Coat the splined shaft with some type of release agent, ie. spray paint or vaseline, and set in a mold of plaster of paris. Remove when set by tapping out, then use this new mold to cast an input shaft out of some more plaster of paris, or a rubber compound. Use this plaster or rubber input shaft to create the keyway with JB Weld in the original piece. When it is set, chip out plaster shaft, or burn or melt out rubber one (if it does not come easily). Then, use original shaft in the new keyway. May be too much work, but look on it as an adventure in frugality. John.

: Thanks for the input guys. I thought about welding, but pulling that ballanced head assy apart looks like a pain in the neck (and the wallet). Under the circumstances I think the saran wrap approach will be the most reasonable. But John, you certainly get honorable mention for originality!
: Stan.

There are several machinists in the dakotas and neb. who do tis type of work. and then it will last. you will be lucky if it lasts 3 min.