I find myself replacing the motor on my 15yo drill press. It has the old d-type shaft, where it is just flatted for most of the length. The step pulley just has a set screw to secure it.
Of course, I could not find a new motor with that style shaft. Everything uses a keyway. I have looked into replacing the pulley as well, one with a keyway already broached, but the existing pulley has a 1.5" tall.. boss? I am not sure of the term. It looks like a shaft collar welded to the bottom of the pulley. The setscrew is in the collar. I have not been able to find a new pulley with anything near that height base.
So, I am looking for thoughts on how to mate these two parts. I think I have the following choices..
1) ignore the shaft keyway, and just file a flat on the other side of the shaft and secure the pulley using the set screw.
2) find a key that just fills the keyway on the shaft, and use that as the flat for the set screw.
3) get a new pulley, and a shaft collar the right height, line up the keyways, and weld it on using a level of accuracy I don't have anymore
4) buy a broaching tool and bushing and cut a keyway in the existing pulley.. I think the problem with this is that the pulley is 3.5" high. that is a long way to try to broach. I have heard of a blind broach? not sure if that is what it sounds like. Plus cost-wise it isn't worth investing much more money in it..
5) send it out to a shop? same cost issue..
In case it matters, 5/8 shaft, 1hp 1800rpm motor, 4 step pulley, 3 pulley gearing..