Removed A/C pulley from 5 bolt crank pulley setup.

[black86glhs]

I figure this has been done before, but I always wanted to see how hard it is to do. Now I know.
I like it. Much lighter pulley setup than a regular non-a/c pulley.
Looks like if you cut a piece of 1/8th thick steel that is roughly 4.75" in dia, you could reinforce the pulley without adding a lot of weight. After you tack it in, drill the bolt holes and then take your time welding the rest of the steel to the pulley to try and lessen warpage. Looks like I am getting some metal tomorrow and trying it out. Oh yeah, I need to fill my welder bottle too.

[Keito]

Did this last month.
I'm not use any extra metal to strengthen it, guess I'm rolling the dice.
I have before and after weights, for that and a few other parts I modified,
I'll post when I get them finished.

[BadAssPerformance]

Cool, sounds like a KC article

[black86glhs]

I want to make sure that no stress cracks form after it is spun up to 6000+ rpm. I'm not worried about the outer part where the belt rides, as that is the same as it was with the a/c pulley on it.

[minigts]

Sounds like you should have taken pics....what the heck man?! Show what you know.

[zin]

Yeah, just do the old car mag trick! After the work is done (and any mistakes are made and corrected), go back and take it apart, then shoot picts of you "doing the work" (perfectly and without errors) as you re-assemble it! Just gotta remember to keep the parts you cut off, or you won't get to show that "being done" in the article...

Mike

[Keito]

Starting weight- 3.582Lbs.
Finished weight- 1.88 Lbs
Butchering up the water pump pulley next.

[black86glhs]

Hopefully my new scale will show up soon. Even so, I have some pics of the tear down.
1st pic is the outer part of the pulley. Took a cut off wheel and cut it off at the holes. Drilled the tack welds from the back of the assembly and a round head carbide bit to try and remove more material from the a/c side hoping it would pop loose easier.
2nd pic is the inner part separated from the a/c pulley.
3rd pic is the center section after it was removed.

[ShelGame]

I did this on my race car back when I built the first engine for it (that was like '03 or so). I didn't add any reinforcement at all, and it's still on the car. Of course, it's only been driven a couple of hundred miles since '03 - it's a track-only car these days.

I thought, though, that there was a Chrysler pulley for AC delete cars? Does it have any reinforcement?

[minigts]

I don't think I understand what is going on here. Do both pulleys have the A/C pulley on the back? I mean, you're not moving one 5-bolt plate to the other are you? Anyone have a finished product or can someone explain what is going on?

[ShelGame]

I don't think I understand what is going on here. Do both pulleys have the A/C pulley on the back? I mean, you're not moving one 5-bolt plate to the other are you? Anyone have a finished product or can someone explain what is going on?

The AC pulley is on the front; it's spot-welded to the main pulley, which has the water pump/alternator 4-rib pulley and the P/S pulley formed into it. I think he just drilled out the spot welds and removed the A/C pulley from the front of the 5-bolt CB pulley assembly. Then, he cut the center out of the A/C pulley to put it back on the main pulley as a reinforcement. At least, that's my interpretation...

[minigts]

The AC pulley is on the front; it's spot-welded to the main pulley, which has the water pump/alternator 4-rib pulley and the P/S pulley formed into it. I think he just drilled out the spot welds and removed the A/C pulley from the front of the 5-bolt CB pulley assembly. Then, he cut the center out of the A/C pulley to put it back on the main pulley as a reinforcement. At least, that's my interpretation...

Well ok. That's what I THOUGHT was going to happen, but then I saw the two pulleys and started thinking he was moving one center to replace the other, but they looked identical! haha And then I thought the way you described and wondered if that would offset the pulley, but realized it's replacing the extra metal that is being removed from the A/C pulley being gone. Thanks for the explanation.

[ShelGame]

Well ok. That's what I THOUGHT was going to happen, but then I saw the two pulleys and started thinking he was moving one center to replace the other, but they looked identical! haha And then I thought the way you described and wondered if that would offset the pulley, but realized it's replacing the extra metal that is being removed from the A/C pulley being gone. Thanks for the explanation.

And, like I mentioned, I did this years ago and never did anything to the center of the pulley and it's still there. I don't think the actual Chrysler non-AC pulley had any reinforcement either.

[supercrackerbox]

I never noticed any sort of reinforcement on the non-AC pulley I have on my Charger.

[black86glhs]

The earlier 4 bolt non a/c pulley does have a thin reinforcement. Besides, the inner section of the main pulley got a little chewed up in a couple places.
Rob, you were close. Everything you said is correct except I'm not reusing the center of the a/c pulley. I cut out some 16ga sheet in a 4 3/4" dia circle to reinforce the setup. Still have to finish that part.

[ShelGame]

The earlier 4 bolt non a/c pulley does have a thin reinforcement. Besides, the inner section of the main pulley got a little chewed up in a couple places.
Rob, you were close. Everything you said is correct except I'm not reusing the center of the a/c pulley. I cut out some 16ga sheet in a 4 3/4" dia circle to reinforce the setup. Still have to finish that part.

Oh, OK. I mis-understood. You're just using the center as a template, then?

[black86glhs]

Actually, the piece I cut for the reinforcement goes out to the first dished portion. It covers more than just the center part. Also, this is a common block pulley. The non a/c, non cb pulley weighed in at 2lbs 3 oz. The modified CB pulley weighed in at 2lbs 3.7oz.
This wasn't trying to make the lightest pulley, it was just to see if I could get it apart and the reinforcement was my way of insuring no fractures take out the center and cause failure. It may be overkill, but that is fine with me.
Also, I was dialing in my welder. I had a couple leaks in the argon supply lines the last time I used it. So it never welded worth a crap. When I post up the next pic, you'll see it still isn't right, but it has good penetration.

[black86glhs]

Comparison photos of the 4 bolt non CB and the modified CB pulley.

[supercrackerbox]

I'll have to see what my factory non-ac pulley weighs.

[black86glhs]

With it all said and done, it weighed in at 2lbs 3.8oz. Just barely more than a non-CB non a/c pulley. Next one, get less material added to lighten in up. It was interesting to do it and I got to use my welder and start to dial it in!!!