Wexmar provides custom pulley machining for V-belt sheaves, flat belt pulleys, idlers, cable sheaves and timing pulley blanks. Our Canastota, New York shop produces CNC machined pulleys on Mazak and Doosan lathes with live tooling, finishing the bore, grooves and hub in one setup so the pulley runs true. We are a direct pulley manufacturer for custom and replacement parts, and every quote is reviewed by a human estimator.
What pulleys do and who buys them
A pulley transmits power or guides a belt, rope or cable. Groove geometry sets belt fit and wear, and bore-to-groove runout sets vibration and belt life. Typical buyers include:
- Power transmission and industrial equipment OEMs with non-standard sizes or bore features
- Conveyor, packaging and material handling builders needing idlers and crowned pulleys
- Maintenance buyers replacing obsolete or custom sheaves
- Defense and government programs with build-to-print pulleys and cable sheaves
How our custom pulley machining works
Turning grooves, bores and hubs
Our lathes turn the rim, hub, bore and grooves in one chucking where the geometry allows, then flip to finish the back side. V-belt grooves for classical and narrow sections, flat belt crowns, round belt grooves and wire rope sheave grooves are cut with form tools or contoured to profile. The Mazak Multiplex 6300Y finishes both sides of a pulley in one cycle for production. See CNC turning.
Live tooling and milling
Live tooling cuts set screw holes, lightening holes, spoke windows and bolt circles for taper-lock or QD bushings. Keyways are machined to standard. Larger or spoked pulleys can finish on our Mazak horizontal machining centers.
Timing pulleys
We machine timing pulley blanks complete with bore, hub, flanges and keyway. Tooth profiles that require hobbing are completed through qualified outside processors, since gear cutting and hobbing are not offered in-house.
Typical pulley materials
- 6061 and 7075 aluminum for light, low-inertia pulleys, often anodized
- 1018, 1045 and 4140 steel for load-bearing sheaves
- 303 and 316 stainless for food, washdown and marine service
- Bronze and engineered plastics for cable sheaves and quiet idlers
Critical pulley features and how we hold them
- Bore fit: bored to a slip, transition or press fit for the shaft, or to the taper for bushed designs.
- Groove to bore runout: grooves and bore are finished in the same setup to keep radial and axial runout low.
- Groove angle and pitch diameter: checked with groove gages, pins and the optical comparator.
- Keyway: width and depth held to ANSI or ISO standards, and centered on the bore.
- Balance: uniform rim wall and symmetric spokes reduce correction needed at balance.
Typical tolerances and finishes
| Feature | Typical tolerance | Tighter on request |
|---|---|---|
| Bore diameter | +/-0.0005 in | +/-0.0003 in |
| Groove radial runout to bore | 0.002 in TIR | 0.001 in TIR |
| Face axial runout | 0.002 in TIR | 0.001 in TIR |
| Groove angle | +/-0.5 deg | +/-0.25 deg |
| Keyway width | +0.002 / -0.000 in | +0.001 / -0.000 in |
| Groove sidewall finish | 63 Ra | 32 Ra |
Values are typical. Pulley diameter, width and material affect what is practical, and the quote confirms each callout.
Design notes
For high-speed pulleys, keep the rim wall uniform and avoid unsupported thin webs, which can chatter during turning. Specify the bore tolerance as a fit to the shaft rather than a nominal size alone. If a pulley will be anodized or plated, note whether groove and bore dimensions apply after finish. For replacements, a belt section and datum diameter are more useful to us than a worn sample.
Secondary operations
Dynamic balancing, heat treat, anodizing, black oxide, plating and powder coat are completed through qualified outside processors. Timing tooth cutting is also routed through qualified outside processors.
Quantity patterns
Pulley orders range from single replacements and prototype sets to production runs of several hundred per release, and matched pulley pairs for a drive can be machined and inspected together. Programs and soft jaws are retained for repeat orders. Related parts include sprockets and hubs and yokes.
Inspection
Bore size, runout, groove angle and pitch diameter are checked with gages, the Mitsubishi optical comparator and our Brown and Sharpe CMMs. FAI in AS9102 format, CMM reports and material certs are available.
Getting a quote
Send the drawing or belt section, pitch diameter, bore and quantity. You can upload a drawing for an instant estimate, and an estimator will confirm price and lead time. Call (315) 400-2654 for pulley questions.