Dia. Mag. Alternator

[z.monkey]

LOL!  Finesse, duh, U underestimate my skills...

[tbird]

http://www.maudlinproducts.com/shims/plastic_shim_coil/plastic_shim_coil_5x20.xml?cat=1273

[z.monkey]

OK, I took a 5/16 inch flat faced punch worked around the periphery of the hole.  Put the punch down, tap tap.  Move it around maybe 15 degrees and tap tap.  Work all the way around the hole once, then fit the bearing.  Still loose, going around again.  Put the tap down, tap tap.  Move it 15 degrees and tap tap.  I had to go around the circle three times.  Always use uniform strikes with even pressure and don't get in a hurry...

So, that's how you reduce the size of a hole in sheet metal.  There are limits to this.  I only had to move this hole 1 mils on each size.  The further you have to move it the thinner the metal gets, so its not gonna work with a larger error...

You can kinda see the strike marks in this picture...

[z.monkey]

I decided to use the Anvil instead of the machine vise.  The Anvil doesn't move as much.  This plate only needed one revolution of strikes, and was perfect.  Its press fit, like it should be, no lash...

Between the Hammer and the Anvil...
http://www.youtube.com/watch?v=PwcS5e0OYQM

[z.monkey]

OK, now I have the bearing refit done.  That only took about 4 hours.  I rearranged the pieces that were spacing the bearing plates from the core.  I calculated the length of the shaft mounting collars, and the seat of the bearing plate mounts, and the shaft is shorter by 10 mils (calculated).  So that's 5 mils on each end of the shaft.  Then the bearing plates bow inward slightly from the blacksmithing process.  When it is bolted together there is no detectable play in any direction.

Now, we are ready to spin...