Loose pulleys with babbitt metal for bearing: surfaces are easy on the shaft, but they have a mean way of wearing out so that they have to be rebabbitted occasionally. That this is to some workmen a puzzling job is evidenced by the length of time required to accomplish the task and the wobbly results after it is done.
The proper and simple way is to bore a hole the size of the shaft in a short piece of plank, and after turning a plug to a neat fit, slip this board on it and face up in the lathe to a true surface. Then turn a shallow groove that will just receive the rim of the pulley in a snug fit. If the hub projects farther than the rim it will be necessary to turn down into the middle of the plank far enough to accomodate the hub so that the rim will enter the groove. In the event of the countershaft having been taken out it is as well to put the board on this and babbitt the pulley on the shaft itself, but in the absence of the shaft a piece of wood turned to the same size will do as well.
When putting the pulley in place one or two thicknesses of paper should be pasted around the shaft before pouring the metal so as to give the bearing a running fit. The paper should not be pasted all over but merely a little streak at the end so that it will stay in position. Sometimes it is hard to get the pulley off the shaft and the looseness of the paper will facilitate this operation. But understand the paper must be smooth and tight when the pouring is done.
One of the common troubles of babbitted loose pulleys is that the babbitt gets loose in the housing and causes a bad knocking before there is much wear in the bearing proper. This can be prevented by having the pulley good and hot when the babbitt is poured so that it will shrink about as much as the softer metal and so be tight forever after.