Well, the day started out $hitty

[Rocket Scientist]

Yes Bill is from Robinson's and Although I am retired yes I was a Tool & Die Maker. A Prototype Machinist for the Military specializing in Heavy Actinide Machining for the Military. Or as I would say Iv'e maid a chip or two

Radioactivity : Actinides
www.radioactivity.eu.com/site/pages/lesactinides.htm
Alongside the fission products found in the core of nuclear reactors there are elements known as actinides, heavy nuclei that also contribute to the radioactivity of ...

OK, this explains a lot of un-answered questions

 

[Ishrub]

Sounds like you had better be on the lookout for Koreans in your neighbourhoods. You could both be guests of the 'coiffed fat one' shortly!

 

[jake shaw]

I tried undercutting some Briggs & Stratton gears with a carbide Dovetail cutter. not very successful, the gears were harder than the knockers of hell. I think grinding is the only way, or normalizing the gear, machining then re-hardening. I would also be timid about deepening the circlip groove. The case hardening is usually only about .015" deep. I was shocked to see the lack of depth in the existing shaft. Various width Shims can be purchased at Machine Tool suppliers, you might be lucky and even find some with the matching spline. Hope some of this helps, good luck.

 

[Rocket3Pilot]

Whatever you guys come up with for a fix, be sure to document everything, part numbers etc. It seems likely that several owners, unfortunately, are going to need this info!

 

[Steel]

Sounds like you had better be on the lookout for Koreans in your neighbourhoods. You could both be guests of the 'coiffed fat one' shortly!

You mean @1olbull ?

 

[Rocket Scientist]

I finally got time to remove the input shaft and get measurements.

Input shaft;

Spline O.D. 29.62 mm
Groove diameter 28.55 mm
Spline minor diameter 25.97 mm
Groove width 1.66 mm
Clip thickness 1.49 mm
Clip O.D. 33.38 mm
Clip I.D. 27.85 mm

Output shaft;

Spline O.D. approx. 31.20 mm (odd number of splines on this shaft)
Groove diameter 30.13 mm
Spline minor diameter approx. 28.02 mm (odd number of splines on this shaft)
Groove width 1.66 mm
Clip thickness 1.51 mm
Clip O.D. 35.34 mm
Clip I.D. 29.83 mm

Due to the odd number of splines you need some more sophisticated equipment than I posses. It is a close approximation.

I also ran a dial indicator on the shafts. .0005" runout on the the input shaft. .001" on the output shaft. I can't find a spec for it in the manual. Seems resonable considering they're running on ball bearings with 75,000 miles on them.

 

[skydog1000]

You mean @1olbull ?

Oh the FATBOY is going to be mad at you

 

[Mittzy]

I finally got time to remove the input shaft and get measurements.

Input shaft;

Spline O.D. 29.62 mm
Groove diameter 28.55 mm
Spline minor diameter 25.97 mm
Groove width .166 mm
Clip thickness 1.49 mm
Clip O.D. 33.38 mm
Clip I.D. 27.85 mm

Output shaft;

Spline O.D. approx. 31.20 mm (odd number of splines on this shaft)
Groove diameter 30.13 mm
Spline minor diameter approx. 28.02 mm (odd number of splines on this shaft)
Groove width .166 mm
Clip thickness 1.51 mm
Clip O.D. 35.34 mm
Clip I.D. 29.83 mm

Due to the odd number of splines you need some more sophisticated equipment than I posses. It is a close approximation.

I also ran a dial indicator on the shafts. .0005" runout on the the input shaft. .001 on the output shaft. I can't find a spec for it in the manual. Seems resonable considering they're running on ball bearings with 75,000 miles on them.

Groove width 0.166mm?? Assume minor typo - 1.66mm maybe

 

[Rocket Scientist]

Groove width 0.166mm?? Assume minor typo - 1.66mm maybe

Not sure how I missed that . Did I mention I've been working long hours ? Thanks for catching that. It's fixed now

 

[mr hunt]

Not sure how I missed that . Did I mention I've been working long hours ? Thanks for catching that. It's fixed now

Kinda explained why the circlip didn't fit...