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Sarah's Personal Cruiser
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Date:  8-23-2015
Number of Hours:  2.00
Manual Reference:  FlyCorvair
Brief Description:  Fabrication and Install of Rear Alternator Pulley

1) The Pulley spacer was fabricated from a 6"" x 6"" x 5/8"" sheet of Garolite G-10, a Phenolic like material but with superior compression and heat properties. The center was marked and a 1/4"" pilot hole was drilled for reference. Using a fly-cutter two shallow groves were made in the surface at 1 1/8"" and 1 5/8"" radius. These grooves will provide a reference for when the two sets of attach holes are drilled. Additionally a 4 1/2"" hole saw was used to partially cut through at the perimiter of the finished part. Eventually this cut will go all the way through but for now it provides a reference of the final size. In this picture it has been trial fitted to a discarded Corvair Fan Pulley (replaced by Harmonic Balancer). All attachments are made with Grade 8 Coruse Thread hardware. Special thanks to WW of FlyCorvair for sharing his discontinued design for a rear mounted alternator to provide insparation.

2) Pulley spacer fabrication complete and and trial fitted to a discarded Corvair Fan Pulley. The three bolts projecting from the spacer are for attachment of the pulley. These three bolts are threaded into self locking T nuts since the backside cannot be accessed.

3) Pulley installed to Harmonic Balancer ...
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Start of Pulley Spacer Fabrication

Start of Pulley Spacer Fabrication

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