The Ford Barn

SAXBY2 · 03-03-2023, 06:29 PM

Any suggestions please for safely cutting thru the spokes on a 1 piece c.i. pulley with engine in the car. Oscillating tool, Sawzall, etc?

burner31 · 03-03-2023, 06:53 PM

In situations like this I've found that it is much safer for me...to have my buddy do it.

Marshall V. Daut · 03-03-2023, 07:16 PM

I assume you are doing this so that you can have easier access to the pulley nut for removal? They can be a bear to reach while the engine is still in the chassis because of the cramped quarters and because the rim and spokes of the pulley make it difficult to use a ratchet or wrench to grab ahold of that nut.
You could use a cutting disc on a drill, but once again, the cramped quarters will limit the use of a drill or even a pneumatic wrench with cutting disc. There isn't room to maneuver the tool and air hose that will always be in the way. The pulley is just cast iron = surprisingly brittle. Years ago in frustration at not being able to cut the spokes of pulley, I placed a thick piece of plywood between the pulley and the radiator to protect the radiator core and covered the pulley with a thick towel. Wearing safety glasses and gloves, I used a heavy hammer and tapped the outer rim of the pulley with a good deal of force, enough to break off a chunk that was retained inside the towel. The secret is to use a HEAVY hammer with mild force. Rotating the engine slightly, I repeated this process until the pulley spokes and outer rim of the pulley had been broken away. You will be almost shocked at how easily the cast iron pulley breaks when struck with the HEAVY hammer! And to think that the pulley rotates at high RPMS thousands of times per minute at speed! It's a near miracle that it doesn't break under the stress. Well, it can - and has to me twice in almost 60 years of Model A'ing. Not a pretty picture inside the engine compartment where the cast iron chunks grenaded into the radiator core, hoses and dented the hood from underneath!
Once the spokes and outer rim have been knocked away, you can access the pulley nut with a ratchet/breaker bar and large socket, or a plumber's wrench. If the nut is really stubborn, you should be able to use a small pneumatic air ratchet tool and socket. It'll still be tight, but there will be tons more room to maneuver than if the pulley were still in one piece.
My suggestion will probably seem extreme to some readers, but it's fairly safe to the car and owner if safety precautions are taken with a towel, safety glasses and thick gloves.
Marshall

rotorwrench · 03-03-2023, 07:53 PM

A person could likely pull it with the right tooling but it is tricky with a cast iron 1 piece pulley. I use an OTC T-bar puller set and a bearing splitter for a job like that.
https://www.fordbarn.com/forum/showthread.php?t=134336

If it's rusted on, I'd heat it to near 250 degrees F and then pour water on it. Several heat and cooling cycles will generally break a corrosion bond. I have a pneumatic recip saw if I'm going to cut stuff. If you have to split it then cut it on the keyway so as not to damage the crank. A good score and a wedge such as a large cold chisel may crack it. That old cast iron was pretty brittle. I'd only do that as a last resort so as not to damage the front main bearing. Pulling the oil pan may help if that's the course of action.

larrys40 · 03-03-2023, 09:11 PM

Quote:

Originally Posted by SAXBY2

Any suggestions please for safely cutting thru the spokes on a 1 piece c.i. pulley with engine in the car. Oscillating tool, Sawzall, etc?

No problem cutting off a 3 spoke 1 piece. Use a metal saws all blade. Generator off and careful on you blade by the engine mount and do one spoke , then rotate crank nut till another spike is up and then the 3rd . Piece of cake have done a number of them in the car.

Vacuum and blow gun remants of shavings
Be sure to blow clean under hood and fenders to make sure there’s nothing to scratch.
Larry Shepard

lrf · 03-04-2023, 12:40 AM

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I'd personally remove the radiator then everything is accessible. I'm finally retired so I have the time to do it right the first time.

ronn · 03-04-2023, 06:08 AM

Im with larry on this one and if you want to go super fast, buy a carborundum blade.
will cut like butter!

nkaminar · 03-04-2023, 07:16 AM

Remove the radiator.

03-03-2023, 06:29 PM	#1
SAXBY2 Member Join Date: Jun 2021 Posts: 55	Cutting off Pulley Any suggestions please for safely cutting thru the spokes on a 1 piece c.i. pulley with engine in the car. Oscillating tool, Sawzall, etc?

03-03-2023, 07:16 PM	#3
Marshall V. Daut Senior Member Join Date: Apr 2011 Location: Davenport, Iowa Posts: 2,112	Re: Cutting off Pulley I assume you are doing this so that you can have easier access to the pulley nut for removal? They can be a bear to reach while the engine is still in the chassis because of the cramped quarters and because the rim and spokes of the pulley make it difficult to use a ratchet or wrench to grab ahold of that nut. You could use a cutting disc on a drill, but once again, the cramped quarters will limit the use of a drill or even a pneumatic wrench with cutting disc. There isn't room to maneuver the tool and air hose that will always be in the way. The pulley is just cast iron = surprisingly brittle. Years ago in frustration at not being able to cut the spokes of pulley, I placed a thick piece of plywood between the pulley and the radiator to protect the radiator core and covered the pulley with a thick towel. Wearing safety glasses and gloves, I used a heavy hammer and tapped the outer rim of the pulley with a good deal of force, enough to break off a chunk that was retained inside the towel. The secret is to use a HEAVY hammer with mild force. Rotating the engine slightly, I repeated this process until the pulley spokes and outer rim of the pulley had been broken away. You will be almost shocked at how easily the cast iron pulley breaks when struck with the HEAVY hammer! And to think that the pulley rotates at high RPMS thousands of times per minute at speed! It's a near miracle that it doesn't break under the stress. Well, it can - and has to me twice in almost 60 years of Model A'ing. Not a pretty picture inside the engine compartment where the cast iron chunks grenaded into the radiator core, hoses and dented the hood from underneath! Once the spokes and outer rim have been knocked away, you can access the pulley nut with a ratchet/breaker bar and large socket, or a plumber's wrench. If the nut is really stubborn, you should be able to use a small pneumatic air ratchet tool and socket. It'll still be tight, but there will be tons more room to maneuver than if the pulley were still in one piece. My suggestion will probably seem extreme to some readers, but it's fairly safe to the car and owner if safety precautions are taken with a towel, safety glasses and thick gloves. Marshall

03-03-2023, 07:53 PM	#4
rotorwrench Senior Member Join Date: Jun 2010 Location: San Antonio, Texas Posts: 16,440	Re: Cutting off Pulley A person could likely pull it with the right tooling but it is tricky with a cast iron 1 piece pulley. I use an OTC T-bar puller set and a bearing splitter for a job like that. https://www.fordbarn.com/forum/showthread.php?t=134336 If it's rusted on, I'd heat it to near 250 degrees F and then pour water on it. Several heat and cooling cycles will generally break a corrosion bond. I have a pneumatic recip saw if I'm going to cut stuff. If you have to split it then cut it on the keyway so as not to damage the crank. A good score and a wedge such as a large cold chisel may crack it. That old cast iron was pretty brittle. I'd only do that as a last resort so as not to damage the front main bearing. Pulling the oil pan may help if that's the course of action.

03-04-2023, 12:40 AM	#6
lrf Senior Member Join Date: Jun 2019 Location: long beach ca Posts: 171	Re: Cutting off Pulley Sponsored Links (Register now to hide all advertisements) I'd personally remove the radiator then everything is accessible. I'm finally retired so I have the time to do it right the first time.

03-04-2023, 06:08 AM	#7
ronn Senior Member Join Date: Feb 2011 Location: NNNNNNNNJJJJJJJJJJ Posts: 6,794	Re: Cutting off Pulley Im with larry on this one and if you want to go super fast, buy a carborundum blade. will cut like butter!

03-04-2023, 07:16 AM	#8
nkaminar Senior Member Join Date: Jan 2012 Location: Western North Carolina Posts: 3,903	Re: Cutting off Pulley Remove the radiator. __________________ A is for apple, green as the sky. Step on the gas, for tomorrow I die. Forget the brakes, they really don't work. The clutch always sticks, and starts with a jerk. My car grows red hair, and flies through the air. Driving's a blast, a blast from the past.