Idler pulley rebuild or buy new?

[dan filipi]

Something like this..

IMAG0848 1

• dan filipi
• Jul 7, 2014

I don't know if I'd want to grind the head off ANY bolt, especially not flat. There wouldn't be any metal left keeping it from pulling through.

New old stock Idlers are looking pretty good at the moment.

 

[dan filipi]

There's a boatload of wheel studs with different size heads, most only slightly larger than the bolt hole.
This might be the best way to solve it.
Time to visit my favorite parts guys and rummage through their collection.
I'll try to get a part number for one that works.

 

[dan filipi]

pidjones » Mon Jul 07, 2014 5:34 pm[/url]":3ot8e4da]
Ngw club https://ngwclub.com/forum/viewtopic.php?t=14186

Too bad many of the links are dead.
Which wheel studs SDbrass tried would help right now.

 

[zman]

The conversion I was thinking of used a countersunk allen bolt of some sort(black in color).. have seen them in austomotive use just not sure where, possibly to bolt the disk to the hub, different then a wheel stud but rated the same as.
This allowed the back to be flat or nearly flat.
Found this link too, not counter sunk allen but looks right for the job.
https://www.trackboltsandnuts.com/suppli ... head-bolts
This is an example of what I was talking about but in the grade you need.
https://www.albanycountyfasteners.com/Fl ... 480000.htm

 

[dan filipi]

Good ideas.

 

[Ansimp]

Here is the link to a full PDF document that is worth it's weight in Gold by NGWs Sandiegobrass that he made back in 2008, there may be some other idler bearings that are suitable now.
https://www.sdb-e.com/TENSIONER/TENSIONE ... LD-JCS.pdf

 

[pidjones]

That's the guide I used. Since I have a mini lathe, bought a 12mm bolt and turned the head down to 14mm and tapered the remainder of the head to fit the countersink in the bracket. Fit like a glove.

 

[joedrum]

cool info need to put that somewhere on the forum

 

[dan filipi]

joedrum » Tue Jul 08, 2014 3:37 am[/url]":3o74j4ig]
cool info need to put that somewhere on the forum

It IS on the forum, in the gallery. I referenced it way back in this thread LOL.
You guys, sheesh. Need to read the posts.

 

[dan filipi]

Ansimp » Tue Jul 08, 2014 1:42 am[/url]":eydfymgj]
Here is the link to a full PDF document that is worth it's weight in Gold by NGWs Sandiegobrass that he made back in 2008, there may be some other idler bearings that are suitable now.
https://www.sdb-e.com/TENSIONER/TENSIONE ... LD-JCS.pdf

That is the same writeup we have in the gallery.
We now have at least 4 links in this thread to the same writeup lol.

Are you reading what I'm posting?
The idler isn't the problem, that is a near perfect fit. Interference with the plate support is the problem.

 

[dan filipi]

pidjones » Tue Jul 08, 2014 3:32 am[/url]":28keral8]
That's the guide I used. Since I have a mini lathe, bought a 12mm bolt and turned the head down to 14mm and tapered the remainder of the head to fit the countersink in the bracket. Fit like a glove.

Since most don't have access to a lathe, I need to figure out what bolt will sit in that recess and have a small enough head to clear the plate support enough to allow belt adjustment.

 

[mcgovern61]

Hey Dan, I found a link to a great...............never mind. :hihihi: :doh:

:smilie_happy:

 

[joedrum]

countersink flush bolts either allen or other type in strong enough grade is the deal here if one can washer and nut the other side its better than stock by far ...this is the reason i said i would never pay 70$ plus for such a cheap but abdicate set up by honda .... plain and simple rip off in all ways of looking at it

 

[ekvh]

Under-kinda-sort-a related. I went to check mine today. They weren't bad, so I fired it up and saw this:[video]

[/video]

 

[dan filipi]

Hmm. Gee cam or pulley bent?
More likely pulley. I have lot's of them if you need one.

 

[ekvh]

Dan, I keep getting booted back to the login page whenever I try to upload a pic??? I replaced the 1200 with 1000 pulleys. No more wobble. I have a pic of the back of a 1200 idler compared to a 1000. The 1200 just looks like it has three more holes in it.

 

[zman]

It also occurred to me that the plate is not all that difficult to make out of 6061 aluminum , even another steel plate could be fabricated then the bolt hole can be countersunk to your specification.
This is a link to another build using the countersunk allen but because of the holes bigger diameter and the need for some "meat" holding the pulley bolt it stick out a little.
https://goldwingdocs.com/forum/viewtopic.php?f=4&t=16423

 

[ekvh]

Works now?. This was a pic of the 1200 and 1000 from the back. They are close, but not the same. Not sure if it matters.

 

[Joep]

Are the pulleys the same size and the holes the same.. if they do in my book they are not that different.. others may have a different opinion

 

[dan filipi]

I came up with a solution that works really well.
It's a combination of what has been posted here and what I found available at Lowes.

I'll post what I did after I get back from this service call.