How did you make the flats with an angle grinder? Did you mount thegrinder or the rotor in some sort of jig? Did you try to balance the rotor,or does a small imbalance matter?
Hi Greg, I drew some layout lines on the rotor before I started with a sharpie and a little square. The first line was in the middle of where I wanted to make the flat. Aside of this were a series of parallel lines, at about 1/4 inch intervals; these gave me a reference while grinding so that I would cut in a straight line, and that the flat would be parallel and along the same axis as the shaft.
As for the setup, I just stuck the rotor in a vise with the section to be "flattened" pointing up and went at it. It's pretty slow going, so you don't have to be too careful about overshooting, just take a few grinds, set back and examine your work, then repeat. Once you get the motion down it's a breeze.
As for balance, I didn't do anything in that respect other than to try my best to make each flat the same width, and didn't have a problem with it.
Jon
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