Fall project... circa 1976 500 rebuild

enyoc · Post by **enyoc** » Wed Oct 16, 2013 6:23 pm

I wanted a project, and boy did I get one. this m5 was used and abused. took the headstock apart today and found the fan sheave rubbing, the floating sheave stuck to the fan sheave, like STUCK! the idler eccentric bearing is busted up, and the speed control is in need of dentures... wish me luck as I dive in!

wa2crk · Post by **wa2crk** » Wed Oct 16, 2013 8:49 pm

There is a guy on E Bay that can repair the speed control handle and it comes out better than new or you can contact Bill Mayo on this forum. I understand that he keeps spares.
The sheaves are either mis aligned or mismatched. Check for worn keyways and/or bent keys. Don't know what the PO did to the eccentric. Must have chiseled to make it move. Anyhow go slow and rest assured that this is the place to come for help. If I still lived in Hanover I could have been of some help.

Bill V

JPG · Post by **JPG** » Wed Oct 16, 2013 9:33 pm

The stuck 'floating' sheave is not uncommon when lack of lubrication allows crud to take over. The key/keyway may also contribute to both the stuck and the misalignment.(lack of lubrication again) You will likely need gorilla tactics.

That eccentric 'is a puzzlement'.

Do get a new gear insert by the guy on e-bay. You will get a different one back unless you request 'yours' back. He is willing, it just takes longer.

billmayo · Post by **billmayo** » Wed Oct 16, 2013 10:25 pm

wa2crk wrote:There is a guy on E Bay that can repair the speed control handle and it comes out better than new or you can contact Bill Mayo on this forum. I understand that he keeps spares.
The sheaves are either mis aligned or mismatched. Check for worn keyways and/or bent keys. Don't know what the PO did to the eccentric. Must have chiseled to make it move. Anyhow go slow and rest assured that this is the place to come for help. If I still lived in Hanover I could have been of some help.

Bill V

I buy from the Ebay seller grany555 who replaces the bad teeth in the speed control handle with a steel gear. He does outstanding work and recommend dealing with him as I have no spares at this time.

I would like to point out that due to manufacturing tolerances (key locations and IDs), you may find that replacing only one sheave may result in misalignment and/or shaft clearance problems. I always match together any sheave set, idler or motor, for this reason. If only buying one sheave, be sure you can return it if it does not fit.

enyoc · Post by **enyoc** » Thu Oct 17, 2013 8:02 am

My speed controller is on its way to Don (grany555)

The sheaves will be interesting, I busted a post off my cheap snapring pliers, so I won't get to the sheaves until I can find another. If the floating/fan sheaves won't come off easily once the spring is off, do you recommend a gear puller?

Any thoughts on sourcing the eccentric idler bushing?

Thanks guys!

JPG · Post by **JPG** » Thu Oct 17, 2013 8:23 am

enyoc wrote:My speed controller is on its way to Don (grany555)

The sheaves will be interesting, I busted a post off my cheap snapring pliers, so I won't get to the sheaves until I can find another. If the floating/fan sheaves won't come off easily once the spring is off, do you recommend a gear puller?

Any thoughts on sourcing the eccentric idler bushing?

Thanks guys!

PM me yer snail mail address and I will mail you one!

Gear puller may work if it can 'get a bite'!

enyoc · Post by **enyoc** » Thu Oct 17, 2013 8:33 am

PM sent, THANKS JPG!

wa2crk · Post by **wa2crk** » Thu Oct 17, 2013 8:36 am

Lots of penetrating oil and persistent urging for the sheaves. The sheaves are aluminum and don't rust. But the shafts; well that is another subject!
Rust on the shaft will bind the sheaves to the shaft. Apply the oil and let the sheaves sit on a bench overnight in such a way that the oil will run down into the shaft.
Bill V

enyoc · Post by **enyoc** » Thu Oct 17, 2013 6:24 pm

Bill you are right - WD40 for an hour and some very mild persuasion with a block of wood & dead blow hammer and the sheaves closed up!

JPG · Post by **JPG** » Thu Oct 17, 2013 7:15 pm

enyoc wrote:Bill you are right - WD40 for an hour and some very mild persuasion with a block of wood & dead blow hammer and the sheaves closed up!

You got an 'easy' one!:D