Stayer. Lightweight crankshaft pulley 4G69.
 

In this topic I want to talk about making the lightweight crankshaft pulley.

Originally I wanted to just buy on ebey. But unfortunately, found nothing suitable for a 4g69. There are a few pieces for the EVO. But with a caveat.
Firstly, they're all reduced size. This is not good. The power steering, pump, alternator and air conditioning will not work properly.
Secondly you have to choose the size of the other belt.
Third, they mainly made in China. Now I will tell you in more detail.
I didn't have to buy a pulley. My friend bought one a year ago this pulley. He gave me a sample.
http://s017.radikal.ru/i442/1603/0c/4547a203c086.jpg
On the pictures it looked not bad. But in fact it was much worse. Nick on the working edges. Low purity of processing. The absence of the protective layer. Small size (125mm)
Also on sale is colored (red, blue, etc.) However, the layer thickness of 5-7 microns. It serves only a decorative layer instead of a protective layer. It did not suit me. I decided to do the pulley.

First. You have to understand something to start from. Weighed the stock pulley.
http://s05.radikal.ru/i178/1603/1e/32da844a6928.jpg

Factory engineers from model to model of reduce weight. For example. Pulley 4G64 weighs 2300 g. The pulley is made of three parts. Outer, inner and rubber damper. In the engine 4G69 inner part made of aluminum alloy.

I made a few 3D models. With different numbers of holes and different shapes.
http://s010.radikal.ru/i311/1603/c0/da7311248483.jpg
http://s016.radikal.ru/i337/1603/ce/d6610924113b.jpg
Then made detailed drawings of the product.
http://s011.radikal.ru/i318/1603/24/6450a09ee5f9.jpg

Next you need to choose the material. I don't know why the pulleys are made of alloy 6061. For the part which works on friction it's not quite right. More properly applied to the 2024 alloy and with heat treatment. In Russia, this has an analogue alloy (Д16T). If you take grade alloys, we will see all the advantages of 2024 alloy over the 6061 alloy. Although it is somewhat more expensive.
Purchased material for fabrication of parts.
http://s008.radikal.ru/i303/1603/57/90f847dc1599.jpg

Started to make.
http://s017.radikal.ru/i403/1603/b9/c65b37af760c.jpg
http://s019.radikal.ru/i607/1603/cc/05422e50544d.jpg
After the item is made, is thermostrengthening in a special oven.
http://s019.radikal.ru/i612/1603/a4/9205fde62ba4.jpg
http://s019.radikal.ru/i637/1603/85/70ce59b1832b.jpg
http://s017.radikal.ru/i400/1603/f9/af34e1e75ac8.jpg
Electroplating is applied to a hard anodic coating (60 microns).
Now the pulley is protected from corrosion and wear-resistant.

Print logos by laser.
http://s010.radikal.ru/i312/1603/41/2b3bcda57c81.jpg
http://s50.radikal.ru/i130/1603/de/cd72c969057d.jpg

Weighed. More than three times lighter. Good result.
http://s019.radikal.ru/i633/1603/6a/1bd3145ccb59.jpg

Further, what would a normal product, it is necessary to produce a package.
http://s017.radikal.ru/i407/1603/b8/c2c60cfe6a9c.jpg
http://s017.radikal.ru/i402/1603/05/71bf4541b935.jpg

The product is ready. You may ask, how much is it? In my case it is $130.
http://i026.radikal.ru/1603/dd/0173c11492aa.jpg
http://s50.radikal.ru/i128/1603/5d/872c14210206.jpg
That's it. Listen to your comments.

the pulley rotates units - power steering, water pump, alternator, air conditioning pump. If you reduce the size (lower transmission), all units rotate at a slower speed. Thus, your power steering develops less force. Worse the water pump is pumping coolant. The generator produces lower voltage. Pump worse conditioning is pumping freon.
Besides, it is necessary to buy the reduced belt length.

My pulley has a fully stock size. It is completely Bolt on. You just have to remove the old pulley and put new one.

very nice, stayer...I may have to pick one up, since mine is a little cracked in the damper, do you have a webstore? or will these be on Ebay? are there any issues exporting your products from Russia, or is it considered a private sale?

Nice work! That is a magnificent piece of work! I will very likely have to buy one of these when I build my next 4g69. Wish these would have been available back before I got my RRM pulleys.

Thank you for sharing your design thoughts and manufacturing process. Very refreshing to see that level of care. Are you in the aerospace industry?

No problems with delivery. A few guys in USA already bought it.
The report is in the 4G club.

No. I'm just an engineer. But complex projects I do at an aircraft factory.