VAP

<center><img src="http://pictureposter.audiworld.com/711/pspulleyjig1.jpg"></center><p>
I finished up my throttle body work today after 2pm and decided to make a new revision PS pulley clamping jig that will save some time when producing these. My old jig used the 3-bolt triangular pattern mounting bolts to clamp the pulley to the jig exactly the same way the pulley is mounted to the power steering pump. The new design features only one, larger bolt which means less time is spent "per-pulley" mounting &amp; un-mounting to the jig. Turns it into a "single-bolt" affair rather than a 3-bolts in/3bolts out per pulley each time one is mounted to the jig. When doing these in quantity thats a dramatic time-savings! The jig base is machined from tool steel. If I made it from aluminum the pilot stub that centers the pulley to the jig would be very short-lived as some material would be removed from it every time I mounted/dismounted a pulley to/from it. The large/thick shouldered washer clamping disc is 7075 aluminum as it has no "wear" spot other than right under where the nut tightens down on it around the M14x2 stud that's permanently (LocTite red) threaded into the steel jig base. In the future, if I do enough of these, I will have to relieve that area and press a hardened steel washer into it that doesen't spin when the nut is tightened or eventually the nut will start to gaul/eat into the aluminimum underneath it due to repeated tightenings.

Power Steering pulleys are "hub-centric" just like our wheels and rely on the PS pump's ground shaft to center the pulley on the pump rather than the bolts. My jig has the same feature incorporated into it. But the height on mine is .010" shorter than the thickness of the PS pulley flange that bolts to the PS pump. By using a large shouldered CNC'd washer with a single large nut I can then torque the pulley to the jig at 125ft/lbs while holding it in a machinist's vise at the 2 flat spots on both sides in the above pic. Those flats also serve to hold the entire fixture with pulley attached when "plunge-milling" the 12 holes for weight reduction. The jig adds HEAPS of structural rigidity to the pulley so it doesn't try to deflect/move away from the end mills when plunge-cutting those holes. Using all larger-diameter fixturing to spread loads over a MUCH broader surface area precludes me "indenting" the pulleys surface where all of these pieces are being pressed into the soft alloy pulley via the high-torque load on the clamping nut.

The bottom round end of the jig is used for lathe work in trueing up any concentric or radial run-out that might be inherent in the pulley. In the lathe the pulley spins and in the mill the pulley remains stationary while the mill moves around the pulley.

VAP

<center><img src="http://pictureposter.audiworld.com/711/pspulleyjig2.jpg"></center><p>

VAP

<center><img src="http://pictureposter.audiworld.com/711/pspulleyjig3.jpg"></center><p>

MikTip

Any available for me 1.8t? ;o)

EDIGREG

Hey! There's a name we haven't seen around here in a while ;]

islingtonaudi

Nice RS6 rims, I just bought some Falken 452s, great tires!