I recently had to make two matching poly-vee pulleys to convert a turret mill to 3phase vari-speed. Having done a similar job on a drill/mill I thought this was going to be easy so I bought a pair of billets of 7075 'Machine Plate' aluminium alloy. These blanks were each mounted in a chuck with 'outside jaws' and then bored to 40mm to fit the pulley mounting spigot on the top of the quill shaft drive, measured at 39.95mm - and an adaptor to extend the new 3phase motor shaft - machined as well. I then machined the extension adaptor to 39.95mm (and checked it) and used it as a mandrel to hold the first of the blanks to turn the steps and 'Vees'.
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