Hi friends!
From the title of the thread is clear about what will be discussed. At the moment there is a spare 4G69 engine. With this engine I'm conducting different experiments. It will also be a great and interesting topic. Probably a couple of months. When I get results. For this project, I try to use all possibilities to increase the capacity.

In this topic I want to talk about making the lightweight crankshaft pulley. I've seen a lot of graphics power, those who set up such a pulley. This gives you about 5-7 HP. And faster acceleration of the engine.

Originally I wanted to just buy on ebey. But unfortunately, found nothing suitable for a 4g69. There are a few pieces for the EVO. But with a caveat.
Firstly, they're all reduced size. This is not good. The power steering, pump, alternator and air conditioning will not work properly.
Secondly you have to choose the size of the other belt.
Third, they mainly made in China. Now I will tell you in more detail.

I didn't have to buy a pulley. My friend bought one a year ago this pulley. He gave me a sample.
http://s017.radikal.ru/i442/1603/0c/4547a203c086.jpg (http://radikal.ru/big/7bb381b4a2784319acf5af6a429ba5fb)
On the pictures it looked not bad. But in fact it was much worse. Nick on the working edges. Low purity of processing. The absence of the protective layer. Small size (125mm)
Also on sale is colored (red, blue, etc.) However, the layer thickness of 5-7 microns. It serves only a decorative layer instead of a protective layer. It did not suit me. I decided to do the pulley.

First. You have to understand something to start from. Weighed the stock pulley.
http://s05.radikal.ru/i178/1603/1e/32da844a6928.jpg (http://radikal.ru/big/56c10ebce12641aeb511b7a15efdb491)

Factory engineers from model to model of reduce weight. For example. Pulley 4G64 weighs 2300 g. The pulley is made of three parts. Outer, inner and rubber damper. In the engine 4G69 inner part made of aluminum alloy.

I made a few 3D models. With different numbers of holes and different shapes.
http://s010.radikal.ru/i311/1603/c0/da7311248483.jpg (http://radikal.ru/big/d25a7f68b05e4c17a3761bb9c770c872)
http://s016.radikal.ru/i337/1603/ce/d6610924113b.jpg (http://radikal.ru/big/4e6b498f78f84f379569e201e6f963e4)

Then made detailed drawings of the product.
http://s011.radikal.ru/i318/1603/24/6450a09ee5f9.jpg (http://radikal.ru/big/c723f02d5a9c46d5854d479a54e17373)

Next you need to choose the material. I don't know why the pulleys are made of alloy 6061. For the part which works on friction it's not quite right. More properly applied to the 2024 alloy and with heat treatment. In Russia, this has an analogue alloy (Д16T). If you take grade alloys, we will see all the advantages of 2024 alloy over the 6061 alloy. Although it is somewhat more expensive.
Purchased material for fabrication of parts.
http://s008.radikal.ru/i303/1603/57/90f847dc1599.jpg (http://radikal.ru/big/6b6044203efb4a0ab63713fd21dd5d18)

Started to make.
http://s017.radikal.ru/i403/1603/b9/c65b37af760c.jpg (http://radikal.ru/big/1b6dd6f8cece4aada9bbce7fb5474b91)
http://s019.radikal.ru/i607/1603/cc/05422e50544d.jpg (http://radikal.ru/big/56c2f96685994c749b5a8531e98f1b14)

After the item is made, is thermostrengthening in a special oven.
http://s019.radikal.ru/i612/1603/a4/9205fde62ba4.jpg (http://radikal.ru/big/41c8659c69b54269ae59818591947fcf)
http://s019.radikal.ru/i637/1603/85/70ce59b1832b.jpg (http://radikal.ru/big/f6cb81b941504b2eb050f46c8620fbbb)
http://s017.radikal.ru/i400/1603/f9/af34e1e75ac8.jpg (http://radikal.ru/big/aa6448fa33e64a3c82680ce78e6d361f)
Electroplating is applied to a hard anodic coating (60 microns).
Now the pulley is protected from corrosion and wear-resistant.

Print logos by laser.
http://s010.radikal.ru/i312/1603/41/2b3bcda57c81.jpg (http://radikal.ru/big/bf3a2de5156040e98423476fd8c1dbef)
http://s50.radikal.ru/i130/1603/de/cd72c969057d.jpg (http://radikal.ru/big/f0f6fb825dca43f1b9cc04de6af3e093)

Weighed. More than three times lighter. Good result.
http://s019.radikal.ru/i633/1603/6a/1bd3145ccb59.jpg (http://radikal.ru/big/d432fa6002b44397b572407ccff173ea)

Further, what would a normal product, it is necessary to produce a package.
http://s017.radikal.ru/i407/1603/b8/c2c60cfe6a9c.jpg (http://radikal.ru/big/28d4995153f0429ba8730f17adec3d7e)
http://s017.radikal.ru/i402/1603/05/71bf4541b935.jpg (http://radikal.ru/big/95cbfcbaf6af4aa1888217871a3a835b)

The product is ready. You may ask, how much is it? In my case it is $130.
http://i026.radikal.ru/1603/dd/0173c11492aa.jpg (http://radikal.ru/big/a05ba3d2e2c04e3a8b3aac3e34bed0db)
http://s50.radikal.ru/i128/1603/5d/872c14210206.jpg (http://radikal.ru/big/1e2c1dd88c7541b6afee7109283d13bd)
That's it. Listen to your comments.

Looks Brilliant and the weight reduction is great.
Interested in one if Shipping isn't a killer.

Looks Brilliant and the weight reduction is great.
Interested in one if Shipping isn't a killer.

I don't know the exact figure, but I think not more than 60$.

https://genophoria.files.wordpress.com/2012/11/shut-up-and-take-my-money.jpg

Seriously, get a whole box of them on the way to us. We'll pay you in paypal credits!

Seriously, get a whole box of them on the way to us. We'll pay you in paypal credits!

What's the point when they don't fit the 6G motors, or do they?

To make the pulley any shape and size is not an issue. It just takes a while. Just need 5 orders and can start.

I am missing the point of doing this but would like to know why this is contemplated.

I am thinking that:
In terms of the overall change in rotational mass coupled to the crankshaft, such a reduction would be minimal.
Would not the rotational energy in the pulley help smooth out the combustion cycle (just like the much heavier flywheel on the other end!).
The energy of such rotational mass isn't lost to the drive train so there is no efficiency dividend.
Only thing might be a tiny bit of difference in the car's throttle response.
Maybe some gain in HP if you can reduce that which is given to the accessories that are driven from the pulley (change in gearing ratios?).

Also a solid pulley is no longer a harmonic balancer - so is this pulley to be a bolt on to a torsional dampener of some sort?

Is it useful on a street car or is it just a bit of HP gain at the expense of a proper design balance?

I'm afraid I'm not enough of my English that thoroughly explain the principles.

For a normal car and a calm daily driving don't need to do anything. Just use a stock car. It need people who have in blood gasoline. )))))))).

Weight Reduction and Less Power(and Fuel) required to spin it presuming common sense prevails.
Worst case scenario, you've spent 200$ on a 1Kg lighter engine component.

+Kw@Engine
+Fuel Economy (Minimal, Depending)
+Better Kw/Kg (Minimal, Depending)

Even a 0.1L/100Km would be worth 200$ to me.

Mostly it is put not for the economy, and to increase the power and throttle response. )))))
On engines 150-170 HP this gives an increase of about 5-7 HP. The 6g engines give approximately 9-11 HP

I'll try to explain.

There are two types of bench testing. One method is a motor stand. Is applied at the factories. The engine installed on the stand. Spins up to full speed. Then removed the power in steady-state regimes. If such a stand to install two different engines, one stock, other with a new pulley. They will show almost the same power and torque. Because power was in the mode of the established speed. The amount of energy released is the same.

The second method is a wheeled stand. So measure the power of most cars. Car set on a stand, and it will accelerate. Here power is measured from the beginning of the acceleration. Therefore, a car with a light pulley, will show higher power numbers.

On a real road this, too, is expressed as on a wheeled stand. A car with a light pulley hits the scene faster than stock. However, for example at a speed of 150 or above, they will be the same.

Mostly it is put not for the economy, and to increase the power and throttle response. )))))
On engines 150-170 HP this gives an increase of about 5-7 HP. The 6g engines give approximately 9-11 HP

So worst case is about 3 kW and best case would be around 8kW at the Engine.
Would still be happy to buy one even at worst case.

So worst case is about 3 kW and best case would be around 8kW at the Engine.
Would still be happy to buy one even at worst case.

I think it should be solved through the administration of the website. All things are possible.

A constant speed dyno will show zero power change.

The engine RPM will be easier to change, so acceleration will be slightly improved. The improvement will be proportional to the rate of RPM change, so most noticeable in low gears and negligible in higher gears.

Idle quality generally suffers with lightweight flywheels, but this would be more noticeable in a four cylinder car than a six.

Quite often, lightweight flywheels make it much easier to bog down on a hard launch. If you want the best 0-100 times, having a heavy flywheel will get your average times down - because it makes it much easier to get consistent launches.

Like all mods, there are positives and negatives.

^^^ All right. It is necessary to apply a set of measures. It's just one of those events.

@ stayer - the product does look very professional.

Thanks everyone for the explanations of why you might want to do it.
No problem understanding the dynamic power distribution aspect of this.
If its for petrol heads that just want a bit of extra take off grunt then I can appreciate the "why not" hobby aspect consideration.

No one touched on the torsional vibration dampening aspect you get with a "normal' pulley.
I assume it is lost with this replacement?

No one touched on the torsional vibration dampening aspect you get with a "normal' pulley.
I assume it is lost with this replacement?

A solid pulley would have no rubber band type dampener.
I'm not sure what it is meant to dampen anyway, I've read that it dampens harmful high frequency vibrations that may damage/break a crankshaft if you use a solid pulley, but it may be there just to make the life of the belts easier.

Mostly it is for comfort. And certainly the crankshaft will not break from his absence. Earlier cars don't have dampers in pulleys

I don't think the harmonic balancer is there for crankshaft strain relief that's for sure.

Rather thinking that the 4 stroke cycle is a discontinuous process.
Meaning the crankshaft is constantly accelerating / decelerating.
Those rapid rotational speed oscillations will cause vibrations in everything coupled to it (2 stroke vibrating motor mowers - extra curricular benefits!).
A tuned dampener is supposed to "cancel" that oscillation from reaching the accessory items and its mechanical couplings.

Be curious if the accessory belts themselves have some dampening effect (at the expensive of increased wear!).

On the up side for petrol heads - maybe the increased vibration and noise is actually desirable along with the extra take off grunt.