Hey Guys,
I finally have my Boss 6 machine cleaned-up and am ready to bolt my servos on. However, my servo motors have 1/2" diameter shafts; whereas the OEM motor pulleys have 5/8" shafts. I know I could spend $200-$300 for some new type-H pulleys to fit the new motors; but I would rather save that money for other things if possible. Yes........I am cheap!! LOL.

See what you think about this idea:

I am thinking about boring the I.D. of the pulleys to 3/4" or 7/8" and pressing in a solid bushing. Perhaps TIG welding/fusing a few locations around the pressed perimeter and turning them clean (if needed). Then I would indicate the teeth of the pulley true on my 4-jaw chuck in my lathe and re-bore the I.D. to 1/2" to fit my motor shafts. I can borrow a small broach from work and cut keyway grooves as needed via my arbor press.

What do you think?? Will it work?? All critical feedback is welcome!!

If anybody has found a cheap source for H-Type pulleys to fit these machines, please share that too.

Thanks,
Wayne