Lightweight crankshaft pulley 4G69
Hi friends!
From the title of the thread is clear about what will be discussed. At the moment there is a spare 4G69 engine. With this engine I'm conducting different experiments. It will also be a great and interesting topic. Probably a couple of months. When I get results. For this project, I try to use all possibilities to increase the capacity.
In this topic I want to talk about making the lightweight crankshaft pulley. I've seen a lot of graphics power, those who set up such a pulley. This gives you about 5-7 HP. And faster acceleration of the engine.
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.
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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.
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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
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Then made detailed drawings of the product.
http://s011.radikal.ru/i318/1603/24/6450a09ee5f9.jpg
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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
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Started to make.
http://s017.radikal.ru/i403/1603/b9/c65b37af760c.jpg
http://s019.radikal.ru/i607/1603/cc/05422e50544d.jpg
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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.
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Print logos by laser.
http://s010.radikal.ru/i312/1603/41/2b3bcda57c81.jpg
http://s50.radikal.ru/i130/1603/de/cd72c969057d.jpg
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Weighed. More than three times lighter. Good result.
http://s019.radikal.ru/i633/1603/6a/1bd3145ccb59.jpg
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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
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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.
