Plenty of lube.
Hammering the boss on the shaft is a possibility, but that'll be a last resort.
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Kick Starter Shaft Repair.
- Thread starter Jim
- Start date
Hammering the boss on the shaft is a possibility, but that'll be a last resort.
Jim, I've cut splines before with a 5C speedy spacer,, Bridgeport and an end mill. I don't believe the kick start splines are the Involute variety and more the simple type that can be cut using an end mill and rotating the spacer to get the correct angular spacing. Basically count the total number of splines on the shaft and divide 360 by that number to get the degree spacing between.
None of which I own unfortunately.
The problem I face is I don't have a good shaft to count the number of teeth . I have the boss, but it only has teeth about 2/3 of it circumference.... and there's a gap cut in it. I'm gonna try and get a tooth count off it, but I could easily wind up a tooth off.
Sumbitch... found a knurling calculator. 
Played with some numbers. Adjusted the final dia to 12.71mm and it gives me a tooth count with an integer of 30.... with a pitch of 1.27mm. So my guess of 1.25mm was pretty damn close.
https://www.machiningdoctor.com/calculators/knurling/
Played with some numbers. Adjusted the final dia to 12.71mm and it gives me a tooth count with an integer of 30.... with a pitch of 1.27mm. So my guess of 1.25mm was pretty damn close.
https://www.machiningdoctor.com/calculators/knurling/
f around with an aluminum shaft til you get it dialed in.
Are all shafts the same for the various years? If so I can count the number of teeth and report back, but someone here must surely have access to one readily available.
1/2" aluminum rod is on todays shopping list.
.I zoomed in on the boss and shot it. Printed that out. Makes it easier...
Count the teeth on one half and multiply by 2. Gives me a count of 32T
Was hoping it'd be 30T... fuck.
Would someone please double check me...
The RD200 shaft is a skinny little sucker... I doubt anyone has one that small.
ps stick a bolt in the kicker snug it "some" make your impression on the aluminum shaft rotate 180 degrees repeat. that should give you the 360 degree tooth map.
It's a fairly popular thing to mark/scribe the OD of your chuck with a degree wheel or make attach one on the back of the headstock. You can get all fancy and drill some holes add a spring loaded detent stop, boom an indexer.
take a look on yootoob for ideas to do this.
It's a fairly popular thing to mark/scribe the OD of your chuck with a degree wheel or make attach one on the back of the headstock. You can get all fancy and drill some holes add a spring loaded detent stop, boom an indexer.
take a look on yootoob for ideas to do this.
I very quickly made a little model, based on a ½" OD shaft, with the teeth being 60⁰, and 30t.
Can change it and send the 3D model if needed....?
Atlas already has that. It's sittin' in a drawer waiting on me to clean, fix and install it.
good 3d printer project; print an index ring that will push fit on your chuck OD or into the back of the headstock.
Good idea!
I have a app that lets me design gears. I'll try that first.
If it doesn't work out, I'll take you up on your offer.
Also as a last resort, do you have any gear manufacturers close by? Maybe if you ask them nicely (using some dead presidents), they'll reverse engineer the boss in their QA lab and tell you everything you need to know about the splines.
Only machine shop around (that I've found) that does small piece work like that would break the bank. I went to them to get 10/32 threads rolled on 16 1/8th" rods (for the Ace project)
They wanted 50 bucks......
.... a rod! That's $800.
Told 'em to fuck off.
That's a goddamn ripoff.
No, that's an "We don't want your little job" quote
PS. Kind of a "Go away Son, you bother me"
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