Woodruff keyway repair

Balders · 2008-04-15T16:13:52+00:00

Hi guysWondered if someone might have some pointers for me on how to repair awoodruff (are they called this in the US? Half-moon shaped disk) keyway ona steel shaft.Background:Crankshaft is steelWoodruff key is approx 5mm thick (3/8ths I think)The alternator pulley bolt (on end of C/shaft) became loose and allowed thepulley to chatter. Unfortunately this has allowed the key to chatter too &has opened out the keyway slightly.I took the pulley, preheated with a MAPP gas blowtorch, zapped it with theMIG and allowed it to cool. I then spent a fair while with needle filesre-dressing the keyway. (Heavy pulley 110A 240V mig, C25 mix)How might I be able to repair the crank? It will have to be done in situ.Would hitting it with MAPP, MIG and careful use of a Dremmel suffice?(I wondered about making a copper key to give me a non-stick surface toweld up to.)I really don't want to weld a key in permanentlyI've used Quicksteel for the time being.Thanks :)

Apr 15, 2008 24 Replies

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aarcuda69062 18 years ago

Fixed a late 80s Suzuki Samari crankshaft that had the same problem some years ago by injecting Moglice

into the worn/boogered area.

We drilled a hole thru the crankshaft sprocket that intersected the key slot and then injected the Moglice with an industrial syringe. Once it cured, we dressed the hole smooth so as not to tear up the timing belt. Ran for years and many tens of thousands of miles.

Took what was left of the cured Moglice and set it on an anvil, then tried to break it with a 2 pound dead blow hammer. Tough stuff, couldn't break it.

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DanG 18 years ago

I had very good luck and excellent service on a piece a bit similar. I had a large stick of carbon that I was able to shape into the "has to fit" part that allowed me to MIG a repair. I would think it would give you good results. Easy to file and shape, a large Universal motor brush might work for your needs.

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Stupendous Man 18 years ago

"Leo Lichtman" wrote > Or, a related idea: Make a key that is tapered, so you can partially insert

Done that. Some Toyota 4 cyls seem to have this problem. A single mom, unable to afford a new crankshaft or even the labor, so I took a larger key and ground it to fit the tapered slot, then locktite-ed the whole mess together. Got her back on the road, too bad for the next owner.

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Balders 18 years ago

Thanks for all the replies chaps. This sounds like a good one to try first, thanks Dan. I wouldn't have thought about using a bit of carbon only copper and ally.

I always like a Plan B preferably followed by a C & D. Gaffer tape failed me this time ;)

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