After the second time that I had to drive the 3/32 pin out of the crank shaft to disassemble I new something had to change. Although I had made a sort of right angle punch to do the job, it was still a bear. I had seen some interesting solutions but this is what I came up with.
I milled two 3/32 x .05 deep slots on either side to the crank shaft then made a keyed bushing. I then soldered a washer on to the end of the shaft at the end of the hex to keep the shaft from moving on the right side. I milled the beval gear block out to accept both the gear and keyed bushing. Now I simply slide the shaft through the block while holding the gear and bushing in place. I hold it all together with a shaft collar on the end of the shaft. Seems to work so far. I'll give it a little more time and see if it lasts. Right now, I'm out of ammo. Big suprise, huh? I'll invest some #4-40 set screws if it's a keeper and get rid of those SHCS's. May someone has done this already and I didn't see the post. Anyway comments or suggestions are always appreciated. Maybe this will give someone a better idea.
Redesigned_20Crank_20Shaft_20Assembly (Medium)-id=1286.JPG 91.51KB 3 downloads