The first of the custom pulleys was completed today. The custom pulleys are aluminum instead of steel and allow for six fitted mounting bolts instead of three fully threaded bolts. Here's an image of the new custom pulley connected to one of the previously used rotors.

The custom pulleys are started from a 10" length of pulley stoc. Below is the stock mounted in the lathe.

I won't go through all of the steps here. The manufacturing steps were outlined in the previous log and updated to reflect the as-built process. All of the photos showing each of the steps are in a Flickr album. Here's a shot showing the part after the machining was complete:

Next, the flanges were put in place and a punch was used to roll over the edge in six spots to hold the flange in place. The bearings were press fit in place.

Here's a shot with the six bolts holding the rotor in place. I'm confident this will solve the issue with the bolts breaking.

The next step is to mount the new pulley onto Goliath and run a test to ensure that it doesn't have any issues. If that test is successful, then the other rotor pulleys can be manufactured.