Countershaft spindle assembly questions

[VTdave]

Decided to disassemble the countershaft to clean the bearings and replace the felt washers. No problem getting the two collars and bearing/race off the right end. At the left end, I've been able to free up the race/bearing and the one collar.

The problem is getting the double pulley off the left end of the spindle to allow me to remove the left race/bearing and collar. That strikes me as much easier access to the LH bearings than trying to remove the middle pulley and then sliding the left bearing off the RH end of the spindle.

I have removed the set screw from the double pulley. By holding on to the middle pulley, I can rotate the double pulley a few degrees on the spindle, until it comes to a hard stop, in both directions. Am I missing something holding it in place? Other ideas about removing it? Thanks.

 

[jbobb1]

No keyway?
If not, maybe check for a second set screw, even in the same hole.
The other thought is the set screw created a burr on the shaft. If so, you could take a drill the size of the threaded hole and remove the burr by drilling into the shaft.

 

[VTdave]

Definitely a burr on the shaft. Was able to deal with that and got the pulley off. Before doing that I just really wanted to make sure I wasn't missing another set screw or something like that. Thanks!

 

[markba633csi]

A useful trick for those setscrew burrs is to take a drill bit that just fits the setscrew hole, a bit you don't mind messing up, and grind it flat on the end to make a dedicated quasi-endmill. Run that against the burr with a power drill being careful not to brutalize the setscrew hole threads. Works well
-Mark

 

[wa5cab]

What I would probably do, assuming that I could get a center-cutting end mill that fit the ID of the tapped hole is to dull the cutting edges from just shy of the end to far enough up the cutter so that it could not damage the threads in the tapped hole. And mark it with an ink marker so that I wouldn't try to use it as an end mill in the future.