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Broken pumps are a great way to get free motors for projects! Got this one for free with cracked pump casting so the motor was bound to be scrapped. In this video I show you how I make all necessary parts to convert this pump to a belt grinder motor and cast a fitting aluminum drive wheel all without using a lathe. Just a little disclaimer: Of course this is not the best motor for a belt grinder. Of course this is not the best way to make a drive wheel and for sure it's also not the safest method to turn a true wheel on a motor. This is just my own way of doing it, I just want to have fun and experiment with tools limitations to prove it can be done with decent results. Fun fact: This drivewheel runs more true than the one I have mounted on the 2x72 belt grinder. And that was turned on the lathe! (mind you, turned by me, so it's no surprise) I just started to list some of the stuff I use for my projects in this amazon storefront: https://www.amazon.com/shop/blackbear... It's affiliate marketing, so if you order something from here you'll help the channel for free! Thank you! Index of operation and materials: 0:37 This part needs to be shortened to expose more shaft 1:26 Clean up the cuts with 2x72 belt grinder 1:44 6mm thick steel mounting plate cut with angle grinder 2:09 Rough mark of mounting holes with spray can 2:20 Mark and center punch precise hole locations 2:40 Drill holes for bolts 3:25 Spacers needed to mount the motor securely 3:52 Mark position of shaft hole 4:00 Drill shaft hole 4:53 Design drive wheel pattern in Fusion360 Tip: Always add drafts to the walls of your pattern. Note: Casting a true hole is hard, even with drafts! 5:08 3D print in PLA 5:20 Clean the pattern with box cutter and sandpaper, the smoother the better 5:44 Talc powder 5:55 Petrobon sand, specific sand made for metal casting Can you see the mistake I made with the mold? 8:15 Molten aluminum, degassed with sodium carbonate and fluxed with specific aluminum flux 9:40 Cut sprue with metal cutting band saw 10:11 Grind off flashing and flattening the back on the 2x72 belt grinder 10:35 Mark the center with a forstner bit wide as the shaft hole in the bottom 10:50 Drill the center hole, this is crucial for the wheel to run true 11:11 With my mistake in the pattern I had to carve out a bit of the back side to prevent the final dirll bit to go sidewat (drill bit move when cutting in one side only) 11:31 Final Forstner bit, rills accurate hole but it's meant for wood so it takes a while 12:00 Grind groove for seger with rotary tool 12:30 Grind groove for shaft key with rotary tool 12:59 Cut key channel in pulley with jigsaw, yep, it works! 13:35 Started to turn the wheel true with an angle grinder but it was too slow 14:00 A sharp chisel works way better 14:26 I found the best one was a small woodworking chisel with a very thin and sharp ege, I guess the less contact area the better it cuts 15:26 Checking for roundness. Good enough for my application! I would suggest against turning the inside of the wheel by hand, it's a bit dangerous. The mass of the wheel compared to the motor rotor for a motor as big as this does not count much for balance. I Checked the wheel for balance and was not able to find a "heavy" spot, so I did not drill any hole to balance the weight better. But yeah, that's was the plan! Thanks a lot for watching, I hope you liked the video! Suggestions and comments are welcome. Leave a like and share to anyone who might be interested! ★Patreon★ / blackbeardprojects ★Website★ http://blackbeardproject.com/ ★Follow me★ Facebook ► / blackbeardprojects Twitter ► / blackbeardproje Instagram ► / black_beard_projects