As far as dimensions go im not much help but heat i can hole heartedly 
recommend. Aluminum moves a lot with temp. The rule of thumb is you can 
heat any aluminum to 60 deg C (not quite burn your hands hot potato hot) 
and not worry about affecting temper. You would be amazed how this small 
amount of heat in a boss will free up a steel pin you couldn't drive out 
with a 10lbs hammer to the point you can knock it out with a good thump 
from your hand.


On 2016-09-23 04:15 PM, Gene Heskett wrote:
> On Friday 23 September 2016 15:21:28 Gene Heskett wrote:
>
>> On Friday 23 September 2016 04:34:35 Andy Pugh wrote:
>>>> On 23 Sep 2016, at 08:02, Gene Heskett <ghesk...@shentel.net>
>>>> wrote:
>>>>
>>>> gave up and put a 3/8
>>>> drill in the holder.  That worked for a starter hole and the bar
>>>> then ran in and tried to uniform the hole, looking decent
>>> Are you trying to use a boring bar without drilling a starter hole?
>>> I don't think they are intended for that.
>> As I found, but the end of its original tip contour sure looked like
>> it could do it, and it did, for about 12 mm's., then became a problem
>> child.  So I drilled a 3/8" start hole, then expended that about a mm
>> before I gave it up last night. So now I need the hit it a couple more
>> times to get a hole to calibrate x with and finish that up.
>>
> Which I am pretty close to now. The hub is made and fits fairly well,
> with an OD where the pulley will be driven onto it of about 43.35 mm's.
>
> And the pulley is bored to about 42.25 mm's when I thought it was past
> time to get off my feet.
>
> So my next question , and considering both pieces are alu, is whats the
> target for the final bore of the pulley for a good tight press fit?  And
> should I heat the pulley and freeze the hub?
>
> Had din-din, beer-thirty now.
>
>
> Cheers, Gene Heskett


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