The flywheel

Time for some heavy metal! The flywheel is 100mm diameter and 25mm thick. I had an ugly lump of steel that was just right for this.

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The lump was setup in a 4 jaw chuck and centered as best as possible. With light cuts to avoid the thing flying out I surfaced the outer diameter to correct size.

 

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Then a lot of passed to cut a 5mm deep recess in the end.

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After a lot of cutting I set the result into the 4×6 band saw. A jack screw served to keep the support plates tensioned so that the short stub would be clamped solidly. 45 minutes of cutting later, I have 2 pieces! The cut was only out by 0.5mm over the 100mm, a result of careful setup of the saw some time ago. With a bit of effort these can be quite accurate machines. Using my spray coolant helped produce a decent looking cut and helps preserve blade life.

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Back to the lathe and centered the flywheel again. Much more cutting and we have a flywheel at last. Drill and ream the 10mm hole and then some polishing to get rid of most of the machining marks.

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The result fits perfectly with no discernable wobble, as it should be.

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