Today, I was cleaning up and saw my 1" belt Dayton sander sitting there, never used. So I turned it on and it vibrated a lot. I checked and the top pulley and idler pulley's bearings are both shot. I happened to have 2 bearings of the same size (6203). So great, I will just replace them.
My first notice was that somehow the outer edge of the existing bearing is thin. It can't be so, so it must be embedded inside the pulley (plastic). I proceeded and pushed out the bearing from the small idler bearing and indeed, it sits inside a groove, and pushing it out effectively destroyed it.
So now I have the larger pulley that I am thinking of should I make a pulley, buy one or manage to replace the bearing without destroying it. The only thing that came to my mind to replace it is heat. Get it soft enough and somehow get it out. It doesn't appear to be a good option.
Maybe a car pulley? There are tons out there. Just find 3.5x1" pulley. Maybe I can make an adapter for the inside hole and it's good to go. It costs more than I would like though and still with lots of work.
If I have the right metal, turning it on a lathe with be a pretty short work. I even looked up 3.5" metal caster wheel to see if I can make use of that, but the middle material is too small for boring out to fit the bearings.
Pouring aluminum is just not my thing, not now I think, but it can be a tempting option.
What would you do in this case? If I can, I would prefer not spend a lot of money on this one.