Sleeve bushing for lawn tractor crankshaft

[Frank S]

When you work on 30 year old lawn tractors often the exact replacements are no longer available.
Such is the case with a John Deere 275 that I am working on it has a Kawasaki 405v 19.5 hp engine that was going bad we found a new Kawasaki 405v 19,5 Hp replacement engine the thing is though the old engine had a 1 1/8" diameter shaft, but the new engine has a 1" shaft.
I'm glad it wasn't the other way round because if it had we would have had to replace the electric blade clutch $400.00 and the drive pulley.
So I just had to make a 3inch long split sleeve bushing.
First I turned it down and bored it out then I split it for the shaft key

No picture of boring and reaming something happened to the picks I took
But it went like this, I purposefully turned it .005 under size then made the bore a few thou. undersize as well, taking into account for the tangent or thickness of the sleeve. From past experiences this should cause the sleeve to fit tighter on the shaft and remain there should the clutch need replacing later on. I will also have to make a shaft key of 1/4 by 5/16" high to correspond with the thickness of the sleeve

[Frank S]

Obviously having a sleeve on a shaft means any attachments driven by the crankshaft are going to require a special shaft key.
I made one by cutting a strip off of a piece so 1/4" thick cold rolled steel and grinding it to size on my belt sander

The sleeve pushed over the shaft

The sleeve and shaft key in the pulley

The key in the sleeve

[NortonDommi]

Amazing how often things like this have to be done. I have a few odd sizes of rectangular key steel as well as the usual square stuff. Good tip about making the fit on the shaft a bit tighter thanks.

[DIYer]

Thanks Frank S! We've added your Split Sleeve Bushing to our Crankshaft category,
as well as to your builder page: Frank S's Homemade Tools. Your receipt:

Split Sleeve Bushing by Frank S

tags: crankshaft

[DIYer]

Thanks Frank S! We've added your Pulley Shaft Key to our Engine category,
as well as to your builder page: Frank S's Homemade Tools. Your receipt:

Pulley Shaft Key by Frank S

tags: pulley, crankshaft

[Frank S]

Amazing how often things like this have to be done. I have a few odd sizes of rectangular key steel as well as the usual square stuff. Good tip about making the fit on the shaft a bit tighter thanks.

Yes especially when having to make repairs to various types of equipment. there have been times when I would find a shaft where a pulley gear of sprocket had been allowed to run lose, causing wear to the shaft and the keyway. It was not always feasible to build up the shaft either by welding or using an exothermic metalizing spray ore even using a product like Belzona shaft repair epoxy. In those cases I might turn the shaft down until true then mill out the keyway to a larger size make a tight fitting sleeve then have to make a step key to fit the new gear sprocket or pulley. For bearing locations and seal lands I made something similar to a micro sleeve although usually much thicker than could be purchased then heated them to allow enough expansion to slide over the shaft after it cooled, turn and polishe ot true dimension

[NortonDommi]

Gotta love that Belzona.

[Frank S]

Gotta love that Belzona.

Ant time you can pull the cross shaft that the track groups of a D9L dozer grind the worn bearing surfaces to make them rough mix 5 lbs of Belzona with 1 lb of iron powder fill in the worn area then machine back to round install new 8inch diameter 8inch long sleeve bearings in the main frame of the dozer install the cross shaft and put the track groups back on then run the machine in a coal mine for 3 years before having to rebuild or replace the $10,000.00 shaft, Then Belzona has my vote hands down