Motor Keyway Messed Up

[Martin Wasner]

From the pic its worn oversized (wallowed out) a lot. That chunk on the end looks like the original sidewall.

Im guessing the key just falls out.

I would personally weld it up and re-machine the keyway.

Skip the welding and just cut another keyway 180º from the original

[Mike Mulville]

Skip the welding and just cut another keyway 180º from the original

Yup that's what the motor repair place said.

[Mike Mulville]

Its the g1023 saw, and likely will fit

Sorry guys I missed this suggestion. That pulley is 7/8" bore and I need 3/4".

[Tom M King]

I didn't look through these for you, and I forgot what diameter you were looking for. I did a google search for 3/4" bore three groove pulley
https://www.zoro.com/search?category...on%20Equipment

[Mike Mulville]

I didn't look through these for you, and I forgot what diameter you were looking for. I did a google search for 3/4" bore three groove pulley
https://www.zoro.com/search?category...on%20Equipment

I just bought one on ebay for $35. Delta and other places wanted $70+.

[Tom Trees]

I had a damaged keyway on my tablesaw motor, the same issue as yours...
I ended up welding and filing the damaged part, this took ages, as I'm not much of a welder.
It was very difficult and the filing was slow, nitty gritty hard work on the fingers.
I wouldn't want to do it again.
worn keyway.jpg
Having a guess, I'd say it most likely happened in the first place because the pulley was not drilled on center.
I had to make a jig as I don't have a metal lathe... to mark file and scrape out the bore on center.
I then made a bush/sleeve to fit into the pulley from a hunk of steel
and turned it on the shaft of the motor.
I then cut a keyway into my "new" pulley and made a key.
In the end my key only fit 3/4 into the pulley/shaft and got stuck.
I tried the "persuader" which led to me breaking some of my pulley...quite a lot of cursing happened.
In the end I got the key out with quite a lot of careless angry bashes.
The fit was so tooight that I didn't need a key
So all that extra work of welding and filing the sides of the keyway, and making a key was a waste of time.

Moral of the story...
Check that pulley bore is on center
file.jpgIMG_20170302_095859.jpgIMG_20170305_170945.jpgIMG_20170312_150328.jpgIMG_20170329_185102.jpgIMG_20170329_212003.jpg

Still running perfect, admittedly I don't use the saw all that much.
Good luck
Tom

[Chris Fournier]

From the pic its worn oversized (wallowed out) a lot. That chunk on the end looks like the original sidewall.

Im guessing the key just falls out.

I would personally weld it up and re-machine the keyway.

There it is! Perhaps you can measure things up and find a key that fits...

[Tom Bender]

Install a new key and lightly weld it to the shaft. First grind to make a little room for the weld.