GermanLook Forums - What's going on in my shop

Hey guys,

Once again I thought I had the car perfect. Everything was working great. Until the other week. It happened like this. I was taking a hot date on a spirited morning (after ;) )country drive. It was great, running perfect. Needless to say something had to happen...

About a block from my house I hear this weird clicking, knocking, and grinding sound :thinking: So I put it in the garage, and not mention it (a guy has to keep his cool and composure. don't need lady friends thinking our cars are unreliable;) ) So at the next available chance I hurry to the car to see what ails it. I found this (sorry for the poor pic):
http://i30.photobucket.com/albums/c3...9.jpg~original

As well as all the material the pulley nut had machined off of it, strew all over the engine compartment. Oil everywhere!. When I left the bugout, I had borrowed a wrench off of Lanner because my pulley nut was loose. I tightened the **** out of it before we left. Never thought twice to torque or loctite it at a later date. Well I should of! The pulley as you can see cracked and bored the snout on the inside of the case out .025"! How do I know this? well I rush to put a new pulley on it, put it on torqued and loctited. After a drive around the block, I stop and OIL EVERYWHERE! :angry:

I take it off, get the caliper out and measure it all up. it's WAY oversize.

What do I do?!??! split the case and machine a sand seal? it was a big issue, how do i repair this!?

My solution was this, I decided to make a pulley that was .025 oversize where it meets with the case. Here is a pic just starting to rough it out:

http://i30.photobucket.com/albums/c3...7.jpg~original

Hopefully this solves my problems! Like many other things, always make sure your pulley bolt is TIGHT!

Alex