The sleeve will sit proud of the top pulley by a quarter inch or so, and that’s the position it needs to be fixed – without some of the bushing protruding from the top, the tension spring will sit at angles. Then slide the upper pulley down onto the bottom pulley making sure it meshes completely. To locate the sleeve, first move the belt out of the way, install the bottom pulley in place, then place the sleeve onto the shaft and let it slide down until it rides on the bottom pulley. I then repeated that on the opposite side with a second set screw. When I reassembled it and ran it through the range, the pulley came off the sleeve again to make sure it would stay in place, I ended up drilling through the tapped hole, and drilled a locating dimple on the sleeve itself. I was able to tap the hole, but I cracked the flange when I first tightened the setscrew, so be careful if you go this route. I couldn’t find a way to re-fix that sleeve in place (nor see how it ever had been – I found no sign of a rolled pin), so I decided to drill and tap a hole for a ¼-20 set screw I had available.
The teeth are a little bit beat up, but I’m surprised it’s not in worse shape than it is. When I took my old pulley apart, I realized that it hadn’t actually broken, but that the steel sleeve was simply floating in the top pulley and so the pulley came loose and was just oscillating randomly up there.
I discovered the other day when cleaning bookmarks in my browser that the Renovo part is finally available, so I ordered one and took apart the stock one which had been sitting here in the unused drill press all that time. Some years ago, I thought my drive pulley had exploded, and found the Renovo part coming soon but after checking back every few months, I gave up and forgot about it. (After writing it out, I'm going to split it into two posts one for repair and one comparing the two pulleys). I have a broken DP350 and the new Renovo part in hand. This is my first post here, and I wanted to contribute to this thread with what I’ve learned in dealing with this same issue.
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