Crankshaft nose upgrade/repair tool

[ilikevwdiesel]

UPDATE: see at the bottom of this post!

A machinist friend of mine has designed and fabricated a tool to cut the nose of your VW diesel crankshaft so it will accept the TDI style pulley. Here is a pic of the prototype:

I used this tool today and it works excellent. Just torque the tool onto the end of the crank with the pulley bolt, put some cutting oil on the broach, and gently tap it thru. It's really slick. I used it on an engine that was on the floor but it should work fine with the engine installed as well.

 In the next couple weeks the machinist will do a production run of a dozen or so of these and they will be available for sale or you can rent one for a period if you like. This thread will be updated as the tools become available.  
  
UPDATE: I just used the tool again, this time on an AAZ crank (the one pictured above is a 1.6 TD core I had kicking around). This crank had to be removed from the engine because somehow it had almost 2mm of taper on the face of the crank snout. A local machinist welded the nose and re-squared the face. After reinstalling the crank I cut the slot with the tool and it's all better. This thing is the bomb. We should have a cost for the tool in the next week or so.

[theman53]

That looks just like Andrew's link in his sig line.

[ilikevwdiesel]

That looks just like Andrew's link in his sig line.

Are you saying this is an imitation of the distinguished gentleman from Flagstaff's crank mod tool? I think not...it's an EMULATION

check with your legal team.

[Quantum TD]

Me rents now!

[GEE-BEE]

Either way Iam in

This would be a great gift for my local shop here in southern calif

It would be great if there was a list of shop's that had the tool so owners could have this mod done

Let me know ?
GB

[rallydiesel]

That's awesome that your making it available for sale/rent!

[theman53]

BTW
I can source the broach if need be. I don't sell alot of tooling, as I am more into woodworking shops, but I am a salesman that can usually get a deal on stuff. All I know about the broach is that it should be very expensive. I only sold one and it was 250.00 to my customer.

[CdnVWJunkie]

I'm def. interested in one.  Any ideas on cost?

[sawedoffgolf]

Do you have a price in mind to buy the tool for? i will take one if it is reasonable.

[starrd]

Do you have a price in mind to buy the tool for? i will take one if it is reasonable.

Me too, depending on price

[ToddA1]

So cool....  curious what the price will be. 

-Todd

[ilikevwdiesel]

I just used the tool again, this time on an AAZ crank (the one pictured above is a 1.6 TD core I had kicking around). This crank had to be removed from the engine because somehow it had almost 2mm of taper on the face of the crank snout. A local machinist welded the nose and re-squared the face.

You can true up the face of the crank by pulling the cam to eliminate the possibility of valve/piston contact and then running the starter while grinding the face of crank nose.

Do you have a jig to do this? How do you keep it true? With this unit there was no way to get around welding it, the timing belt was rubbing on the inside of the crank pulley and the alt belt hit the lower timing cover. It was JACKED. There should be several of these tools for sale by the middle of Nov, hopefully a price sooner.

[ilikevwdiesel]

I wonder if there's some kind of end mill cutter that would slip over the nose of the crank and keep it straight while the motor spins over? I am going to the machine tool supply and look.

[starrd]

Will you be including the broach with your offering?  What size did you use in your design?

[ilikevwdiesel]

Will you be including the broach with your offering?  What size did you use in your design?

I'll only supply a broach if we decide to rent the tool out (not 100% sure about that part yet). If someone is going to buy one of the tools they might as well source the broach themselves from McMaster Carr or some company that sells online. The broach in the pics is 6mm I believe, I didn't buy it my friend did.