Custom Idler Pulley Machining for Honda Engine Mini

The Problem

The customer is building a late 90s Honda engine into a 1970s Mini and needed a custom idler pulley setup to clear the surrounding components.

The new alternator runs a serpentine belt, but this conversion required a pulley and stem arrangement that could not be bought off the shelf.

The Engineering Solution

Pinney Engineering Services manufactured the custom idler pulley components using customer-supplied measurements, photos, sketches and online reference information.

We also provided input on the design so the pulley, bearings, stem and brackets could work together with the right clearance and alignment.

The Custom Idler Pulley Machining Result

The finished result was a free-spinning custom idler pulley with a stem and oversized washer to help keep the setup as rigid as possible.

An extra stem without a standoff boss was also manufactured, giving the customer another fitment option if that worked better during final installation.

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