Generator reassembly help

[tbonetoby14]

First post here:

I recently got a new Bosch 12v generator for my 67 sunroof. It came with some woodroof keys on the pulley and fan sides but they seem to be too big for the pulley and fan hardware. I'm using the old pieces from the other generator I had on the bug and they don't seem to fit. I took one of them off and compared it to the old keys and the new ones seem to be wider and won't fit the keyways on the pulley or fan equipment. It also won't go back in the key grove as well as it was before I took it out. I've watched plenty of videos on reassembly and they all make it so easy. Am I doing something wrong? Do I need to get new hardware and a new pulley that fit the keys? Can anyone give me some insight on this please?

[slayer61]

I lost one of the woodruff keys when swapping mine. For like $12 at the local ranch and farm supply, I bought an entire assortment of metric ones and found the missing part in the kit. To me, it was easier and faster than trying to find an original replacement... as they say... YMMV
_________________

[aquifer]

Run a file or emery cloth over the keys to whittle them down a touch. Maybe scrape the edges of the keyways with a screwdriver too. Unless you mean that the keys are clearly a size or two too large, in which case you'll need to find the right size. But I suspect it's just imperfect machining.
_________________
Project vehicles:
1967 Beetle #1. Bought in 2024, mostly original, October 1966 build date. Java Green.
1967 Beetle #2. Bought in the mid 80's, restored myself in the late 90's, June 1967 build date. Java Green.
1998 Jaguar XJR. Bought in 2015, rust free AZ car, refurbished myself. Driven in nice weather.

Parts needed:
Original brown rubber floor mats for a '67
Original gazelle seat upholstery for a ‘67

[esde]

I've definitely had to file keys and keyways to get a nice fit in the past..
_________________
modok wrote:
Bent cranks are silent but gather no moss. I mean, ah, something like that.

[Cusser]

I seem to remember Ace Hardware by me having metric woodruff keys in the little drawers.
_________________
1970 VW (owned since 1972) and 1971 VW Convertible (owned since 1976), second owner of each. The '71 now has the 1835 engine, swapped from the '70. Second owner of each. 1988 Mazda B2200 truck, 1998 Frontier, 2014 Yukon, 2004 Frontier King Cab. All manual transmission except for the Yukon. http://www.thesamba.com/vw/forum/album_page.php?pic_id=335294 http://www.thesamba.com/vw/forum/album_page.php?pic_id=335297

[tbonetoby14]

Yall think it’s just a machining error that needs a little filing? The left key is the one that came with the generator. It just seems way bigger that the one from the original key. it also seems like that keyway on the shaft on the shaft is a bit bigger which is causing the old keys to now stay in place.

[viiking]

Held flat against an angle grinder or bench grinder gets it down close to what you need. Do a bit at a time and then make sure you are parallel. Use pliers etc to hold it to save your fingers.Then final finish with a file.

Alternatively just spend a lot of time with a file.
_________________
1968 1500 RHD Lotus White Beetle since birth. In the hospital for major surgery
1966 Lancia Flavia Pininfarina Coupe - in the waiting room
Discharged: 1983 Vanagon, 1974 1800 Microbus,1968 Low Light,1968 Type 3

[gt1953]

File for sure as you will have more control...sure it may take longer but in end with the perfect fit.
_________________
Volkswagen: We tune what we drive.
Numbers Matching VW's are getting harder to find. Source out the most Stock vehicle and keep that way. You will be glad you did.

72 type 1
72 Squareback
({59 Euro bug, 62, 63, 67, 68, 69, 73 type ones 68 & 69 type two, 68 Ghia all sold})