Geeze, $50 for a drill bit...most machine shops around here are $75/hr, the fancy waterpump is $400, or I could just try and weld it for free. Hmm...

 

weld the end, and then drill a hole perpendicular just far enough thru the pulley material to get to the shaft and weld it, sort of like a body spot weld. Rotate 180 and do it again on the other side, break it after that and id say you might as well just go buy a fancy waterpump...

 

Yea I think I may try that actually...might do 4 though instead of 2.

Im selling my old turbo cam that I loved to fund a new blower cam if anyone is in the market. Specd by PatG, 226/226 605/605 117. Drive great and made great power.

 

Use an EDM drill...

 

When I ripped mine off, it was welded all the way around. If I was to do it again, I'd find a way to get the pulley off, grind a chamfer on the shaft, reinstall the pulley and give it a max penetration type weld.

 

Thats not a bad idea actually...too bad they dont sell the pulley separately.

 

I would pin it like a crank and then weld it.

 

Alright so I ended up actually finding a 5/16" carbide bit in my tool box which I think is from the magnacharger crank pin kit I used 5 years ago. I knew that would come in handy eventually. Jeebalow was right to hold it very fixed...I cracked the bit in half when it was almost all the way through. Part of the problem was the bit was pretty short, so the drill chuck hit the pulley so I couldnt get a straight angle on it. Cut through the shaft like nothing though. 5/16" is a little bigger than I wanted, but I think it will be fine.



I got a piece of 5/16" rod and cut it a little longer than needed and welded it in there and also put 4 welds on the end of the pump snout to the pulley. Not a pretty enough weld with my mig for me to show off, but if it breaks its going to have to rip the pump shaft in half and not just spin off the pulley.



Unfortunately this pump is one of the early ones with the one piece thermostat, so thats annoying. This is also a good chance for me to reinstall the heater lines.

 

I was worried about the 5/16" being too bit and the shaft just breaking in half, so I got another pump and a fancy end mill bit and did what he suggested.



Im gonna keep the one with the 5/16" as a backup

 

Looks good! Hopefully that does the trick, much better than the $400 waterpump.