FANCY "CLUTCH" LEVER and STOP

 

Can't say much about it that you can't already see. I just cut the top piece of the original then welded in a piece of 1/2 inch mild steel rod. The extension piece was actually cut from an old cup head bolt. Down the bottom end I filed a flat where the grub screw holds the lever in place, everything is nice and tight so the shaft and extension piece can't turn.

 

I machined some of the thread off of an M8x1.25 set screw, just left enough thread for the thickness of the plate. Obviously, if one puts a stop pin in then one has to make sure that the "clutch" lever is still going back far enough that the tensioner is able to go to full tension without hinderance.

 

As I was screwing the screw in I slid a short piece of plastic tube on, just before it was all the way on I put a drop of super glue on it to make sure it doesn't work it's way off. These minor modifications mean I don't have to reach back so far to grab the lever and if it slips out of my hand when applying drive it doesn't fly back too far. Now that I have made a larger diameter tensioner pulley I can move this stop pin a bit further forward.

 

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