belt tensioner -- rebuild possibility

[claw45]

G/Day to all -- first am newby to site -- have noted worn bearings in pics of subject tensioner and am wondering if any one has rebuilt the worn sections by turning up some replacement o/s bushes & re-bored the worn bosses or is the internals of the piston unit shot as well? -- at abt $ 400 for the part a simple re-machine would seem feasible. Any comments - -- BTW this is a great site -- so helpful & friendly ( Tony is one hell person ) CONGRATULATIONS TA ALL. .......... Regards Jim. ( Oh!! 03 gu td30
120k no issues.. yet! )

[YNOT]

Thanks for the kind words Jim.

I guess anything is possible as far as rebushing the tensioner strut but I don't know of anyone who has tried it. I think I still have the strut pictured in the other thread in my shed if you wanted one to practice on. As far as I know the internals of the strut usually outlast the bushes.

The bearing in the pulley attached to the tensioner also have a habit of failing but the bearing CAN be replaced without replacing the complete pulley.

Tony

[claw45]

G/Day Tony -- from my observations those words are well & truly earned !!! - I have a fairly comprehensive home shop ( lathe mill etc etc ) seemed a waste to not recon this part -- I know it is an ongoing issue -- it sure looks repairable from the pics. As I am retired ( ex. mining engineer ) I play in the shop regularly still design & build some obscure tooling but mostly just help out like minded mates. Do a lot of caravanning ( mit boat on top --lotsa time up your way ) will possibly be heading up to emerald soon ( missed my winter fishing jaunt to townsville -- house renos !!! yikes -- if so where are you situated we may be able to meet & Iwill give that part a tune up on the mill & knock up some bushes to match-- nothong to loose -- what do you think -- whoops maybe this is not the right place to post this reply ,if so please accept my apologies--not used to these sites- Regards Jim.

[beansathome]

i have just replace the pully and tensioner shock thing on mine her is a pic of what it looks like in pieces. not sure if this will help u sounds like u have things sorted lol

[beansathome]

G/Day Tony -- from my observations those words are well & truly earned !!! - I have a fairly comprehensive home shop ( lathe mill etc etc ) seemed a waste to not recon this part -- I know it is an ongoing issue -- it sure looks repairable from the pics. As I am retired ( ex. mining engineer ) I play in the shop regularly still design & build some obscure tooling but mostly just help out like minded mates. Do a lot of caravanning ( mit boat on top --lotsa time up your way ) will possibly be heading up to emerald soon ( missed my winter fishing jaunt to townsville -- house renos !!! yikes -- if so where are you situated we may be able to meet & Iwill give that part a tune up on the mill & knock up some bushes to match-- nothong to loose -- what do you think -- whoops maybe this is not the right place to post this reply ,if so please accept my apologies--not used to these sites- Regards Jim.

looks like u poested in the right place.
this is the best forum to make mistakes, no one is rude and much more willing to help if u are lost in how things work on here.

[the ferret]

Hmmm, dunno about that mate, time, materials, gett'n it right and confidence in ya product, I would buy genuine for a part as important as what you are considering repairing.
Then again, I don't know you or of your expertise, I just know that as a fitter & turner, I'd leave it alone fer now.
I would also welcome discussion on the subject, best of luck with it if you decide to procede.
The Ferret.

[GlennWilliam]

G,day Jim,

I have just had a go at fixing my Fan Belt Tensioner off my 2000 GU ZD30 I thought there's no harm in having a go and saving a few dollars at the same time.

Here is what I did:

1. I replaced the bearing and re-used the old pulley - CRF Bearing Supplies - Cost $8.00

2. The tensioner strut bottom bush was stuffed so I brought some solid nylon bushing about 50mm long and just a bit over size round and with a small file I filed it down to a nice snug fit and what I would call the shape of a cotton reel so the outside ends were slightly bigger than the center. I than cut it to length used my vice to push the bush back into the strut than re-drilled the hole back in the center of the new bush to take the small metal inner sleeve. Nylon Bushing CRF Bearing Supplies - Cost $4.00

3. The tension spring in the strut to me still felt good so I pulled back the rubber on the strut used some carby cleaner to flush out all the old crap than gave it a very light grease.

4. Put it all back together and it's working like new. It took me about 1 hour and total cost was $12.00 it works for me.:)

Note: I'm not saying this will work for everyone but it did for me so you can only give it a go and see what happens.


Glenn

[the ferret]

Nah that sounds good mate, just goes ta show what ya can do when ya need to eh?
There is another product out there called "acetal" I use this for bearings and pulleys on boat lifters, very durable and hard but good to turn, I use this instead of nylon.
Some boat lifters lift 5 ton boats on a pulley 150 dia, 25mm thick with a 25mm bore, running 10mm stainless cable, so as you can see, it's very strong.
Cheers, Ferret.

[YNOT]

G/Day Tony -- from my observations those words are well & truly earned !!! - I have a fairly comprehensive home shop ( lathe mill etc etc ) seemed a waste to not recon this part -- I know it is an ongoing issue -- it sure looks repairable from the pics. As I am retired ( ex. mining engineer ) I play in the shop regularly still design & build some obscure tooling but mostly just help out like minded mates. Do a lot of caravanning ( mit boat on top --lotsa time up your way ) will possibly be heading up to emerald soon ( missed my winter fishing jaunt to townsville -- house renos !!! yikes -- if so where are you situated we may be able to meet & Iwill give that part a tune up on the mill & knock up some bushes to match-- nothong to loose -- what do you think -- whoops maybe this is not the right place to post this reply ,if so please accept my apologies--not used to these sites- Regards Jim.

I've just been down to the shed and found the strut so if you want it, it yours. As you say, nothing to loose and Glenn has already proven it can be done.
I'm out near Beaudesert and work as a (very) mobile mechanic so meeting up shouldn't be a problem and it would be great to meet another forum member.

If you need any help finding your way around the forum just let us know. Your thread is in the right place but even if it wasn't we would move it for you.

Tony

PS, Off topic but I think you would get on well with my Dad (he lives closer to Brisbane) who also has a machine shop set up in his garage. Check out the 1/4 scale tractor he hand built from the ground up.

[claw45]

G/Day beansathome-- thanks for heads up on your repair -- from pics it appears that only bushes may have been worn -- only too easy to replace --
but note the ferret advice & if possible use Aecetal ( as opposed to nylon ) for replacement bushes -- on Tony's photo the actual " journal / clevis ends also appeared worn & some minor machining would be reqd . Congrats on your repair -- replacement ( especially at what appears to be exorbitant cost ) of whole system appeared extravagant waste. Regards Jim.

[YNOT]

G/Day beansathome-- thanks for heads up on your repair -- from pics it appears that only bushes may have been worn -- only too easy to replace --
but note the ferret advice & if possible use Aecetal ( as opposed to nylon ) for replacement bushes -- on Tony's photo the actual " journal / clevis ends also appeared worn & some minor machining would be reqd . Congrats on your repair -- replacement ( especially at what appears to be exorbitant cost ) of whole system appeared extravagant waste. Regards Jim.

Correct, the insert that goes in the middle of the bush is also worn.

Tony

[claw45]

G/Day The Ferret,
Gee mate 'time on m/c's say miller 15 min ( no real set up issues ) lathe for 2x bushes Acetal ( cuts & finishes dreamy ) 20 min. -- mtls say $ 5.00
don't look too bad --- BUT haven't had a look at actual part to evaluate structural integrity in journal area although from photo looks ok. -- some quick calcs say we don't need lots of parent metal to far exceed expected loads -- looks like Glen William just jury rigged his with apparent success
will assess part when in hand and talk later. RegardsJim.

[claw45]

G/Day Glenn. thanks for posting your repair-- done a good job by the sound of it -- all relevant to the designed function of that part ( non rotating uni-directional compression ) you may have to add The Ferret's suggestion of Acetal bushes in the near future as the nylon may prove ( as original ) too soft -- I suspect what happens with this part is excessive wear of nylon bush allows eccentric load of idlet pulley & destroys idler bearing ---
really Nissan Design fault should possibly have been a recall --- if it was Ibet they would soon have supplied a repair kit PRONTO.- -- FULL MARKS for your innovation. Regards Jim.

[beansathome]

G/Day beansathome-- thanks for heads up on your repair -- from pics it appears that only bushes may have been worn -- only too easy to replace --
but note the ferret advice & if possible use Aecetal ( as opposed to nylon ) for replacement bushes -- on Tony's photo the actual " journal / clevis ends also appeared worn & some minor machining would be reqd . Congrats on your repair -- replacement ( especially at what appears to be exorbitant cost ) of whole system appeared extravagant waste. Regards Jim.

i wish mine was only the bushes. when i pulled it off the car it literaly fell apart i had to cut the belt to get it off. the center shaft in the tensioner was actualy bent and worne down.
so i had to replace it or i would have looked at just the bushes.. i dont think any one relises how easy this is to repair on there own.
i would love to have some spare bushes on hand. its a commen problem

[claw45]

G/Day Tony, OK mate ,put the part in your truck -- will be heading to warmer climes in few weeks -- have to go thru Moree --will swing over to your district & meet -- a mobile mechanic yes figures - too wide experience repertoire to be in dealership or similar. -- from other replies a repair / change over replacement for this item ( s) looks feasible. would be good to have a couple in the kit.-- I think I can re-design/construct original to eliminate defect or at least extend service life to that which Nissan has /was known for. Being a mobile mechanic you should PM me on jbuild45@yahoo.com.au . BTW should you ever wish for a career change you would make a great candidate for a training officer in the Coal industry.
on OT that work done by Dad is awesome -- might be able to meet the master!! Regards Jim.

[claw45]

G/Day beansathome, will be doing some work with this system soon -- will cut a few extra bushes when on m/c & will send you a couple .
Will let you know how all progresses.

[beansathome]

G/Day beansathome, will be doing some work with this system soon -- will cut a few extra bushes when on m/c & will send you a couple .
Will let you know how all progresses.

thanks heaps. let me know how much i owe you

[claw45]

wont be any sweat when set up --$ nil -- pleasure to help Jim.

[the ferret]

Just be wary mate, there are about six grades of Acetal, some are soft like the green, some are a bit harder like the blue, there is black and white.
Some turn off with an endless swarf and are a pain as they fly everywhere and wrap around the chuck, you need to back off every few secs to break the swarf.
I use a white one, can't put ma hand on the code number, but it comes off in a powder form, is very hard and you can get a good finish off the tool, standard Hi-speed tips are good, wear a mask.
Rpm about 1500 seems the go but watch the heat, tends ta drag with being gready, fine cuts seem to work better when close.
Cheers, ferret

[claw45]

G/Day mate, thanks for the info -- you are spot on -- I have the black in stock is hard & wears well - used it for replacement bushes on conveyors -- given good service,machines well -- the white you mentioned might be better if it is harder as I suspect original is crushing out due to constant static load -no rotation to speak of -- haven't seen part in the skin yet-- will let u know when am at it. Regards Jim.

[the ferret]

Jim, There are a few different grades in the black as well, you need the one that turns off like cast iron turns, a bit powdery, some will absorb oil or water and swell. How do you reckon Phosphor bronze would stand up to the load?
Cheers, Ferret.

[claw45]

Crikey Ferret , you must be a mind reader was just now scrounging around in the scrap bin for a piece off-cut of bronze-- reckon it would be bees knees. Since retiring I have really enjoyed getting back at machining really shows how much you don't remember ( left m/c shop 1973 -- mec eng & mining eng then till2005 ) looks /sounds as though you are at it professionally & do some design/fab as well. What type work do you do -- is it similar to Tony . All on hold till I get sample part from Tony. -- have you considered constructing exchange service in WA.? -- May not be feasable for some of reasons as you alluded to in previous post. The Black that I have turns beaut but still runs a stringy swarf so it must still be a grade or two softer than optimum -- will call by old shop & see what offers there. Cancelled my professional indemnity in surance 30 june so no more charge out jobs for me .-- still do some design at arms length ( pays for toys etc. LOL. )-- GREAT SITE THIS --soooo helpful & participants are so generous of spirit . Regards Jim.

[the ferret]

Hi Jim,Nah, my days under the bonnet are long gone, I just work on my invention, The Ferret deflator.
I also make light brackets and bibs n bobs, use the lathe most days, lots of welding etc and hang'n out on this forum,
Yes they are a great bunch on here fer sure.
By the way, phosphor bronze is self lubricating whereas normal bronze isn't, but as a machinist, you would know that.
Don't be misled by the soft swarf on the acetal, it'll take a finger off as quick as stainless.
Cheers Rod.

[claw45]

G/Day Rod, Yep up to speed on the bronze - used to spec as seals on hyd cylinders ( 900 ton) in coal mining .
O/T do lots caravanning & have discovered a design fault in the suspension system as used by thousands of vans ( happened to mine) so dropped it into repair shop ( van specialist ) & was alarmed at the proposed repair technique -- stopped the process , enquired as to why a much simpler & hugely superior fix was not used& he said that they hadin the past, tried to accomplish the repair, as I wanted ,but in so doing had about 12 shop hours invested so aborted & just went with the accepted fix. could not accurately drill necessary holes) -- I held repair over pending solving his problem.
I have subsequently designed & am in the process of building a jigging system to do the job properly -- will have working prototype next couple weeks ( been into house renos last 8weeks ) & he will test run on my van -- if successful I will build a few & sell to selected dealer/repairers.
Where I am going with this is that you may be interested to build a few & add to your inventory-- just keeps the m/c's going & when on the move can call on a dealer/repairer or two ,keep ya young !!! ha ha -- I don't want any $ would get satisfaction that poor unsuspecting van owners are getting propper job done ( there are literally thousands on the road who don't know why their tyres scrub or springs are breaking !!! yikes -scary to me -- will keep u posted on result of test run. BTW thought Tony may be interested - his dad can knock up the jig & he can go from there.
Regards Jim

[the ferret]

Hi Jim, I would be interested in the workings of it, altho I dunno if I have the time to build them.
You could register the design and sub them out to a Machine shop/fabricator.
Don't flash it around at all as you may need to patent it.
Cheers Rod.

[claw45]

Hey Rod. Been down that patent line in another life -- but as I said if it works as expected ( i'm sure it will ) only too happy to pass it on to deserving persons especially if will be of benefit. M/C is simple -- only one piece of precise turning but a miller is also reqd to dress one face -- could do it on larger ( big ) lathe & flycut. Really just enjoying using owm m/c's &solving the problem. Regards Jim

[claw45]

Rod , an off topic but of interest -- was nearly a close neighbour of you -- bought canal block in Sth Yunderup abt 6 yr. ago to be closer to my kids (Perth & Albany ) but I could'nt get a builder to start on construction for 2 years & would not fix completion or final costing -- what a schmozzle so we ditched the idea & sold the block . Was looking to catching all those crabs from my jetty . Small world really. Catch ta later Jim.

[kroski]

claw45, I sent you a pm, have a look. Cheers

[the ferret]

Rod , an off topic but of interest -- was nearly a close neighbour of you -- bought canal block in Sth Yunderup abt 6 yr. ago to be closer to my kids (Perth & Albany ) but I could'nt get a builder to start on construction for 2 years & would not fix completion or final costing -- what a schmozzle so we ditched the idea & sold the block . Was looking to catching all those crabs from my jetty . Small world really. Catch ta later Jim.
Well, tie ma face to an ant hill and smeer ma ears with jaym, small world,
Plenty crabs in the summer, if yer over this way, call in fer a crab fest, I'll show ya ma 1949 Rapson and Dutton lathe, ya probably done ya time on one.
Cheers Rod.

[claw45]

G/Day all -- Quick update -- made some replacement bushes today -- the unit appears as new -- the material was supplied by another member but as I recollect it was Nylatron -- will make some more from Acetal nuw that I have reqd. dimensions. Jim.
PS. this is in no way a major refurbishment .. just need access to lathe. ( provided journals are not worn.)

[patch697]

G/Day all -- Quick update -- made some replacement bushes today -- the unit appears as new -- the material was supplied by another member but as I recollect it was Nylatron -- will make some more from Acetal nuw that I have reqd. dimensions. Jim.
PS. this is in no way a major refurbishment .. just need access to lathe. ( provided journals are not worn.)

Cheers for the update Jim.....

[patch697]

G/Day all -- Quick update -- made some replacement bushes today -- the unit appears as new -- the material was supplied by another member but as I recollect it was Nylatron -- will make some more from Acetal nuw that I have reqd. dimensions. Jim.
PS. this is in no way a major refurbishment .. just need access to lathe. ( provided journals are not worn.)

Some pics would also be good mate if you could.

[beansathome]

hey this is off topic but do u recon u could make some of theese

http://www.ebay.com.au/itm/HID-CONVERSION-ADAPTER-LIGHTFORCE-H3-NEW-ABR-/310346901336?pt=AU_Car_Parts_Accessories&hash=item48421de758

i want to convert my light force 170 to hid ??
i prety much only need to have the oter dimiter machined i can drill in my drill press

cheers ben