The Model A arrived with a complete gearbox, apart from the kickstart spring, cotter, and spring shroud. The kickstart shaft was also strangely long and fitting the lever left the kickstart pedal very low, since the flat for the cotter was in the wrong place.
What we are trying to here is produce a replica of the 'Panther' shaft we have, but shorter and with the kickstart lever cotter in the right orientation.
A close up of the pawl, the pawl spring with it's plunger and the two-diameter pawl pin:
This is the flat for the kickstart lever cotter. The shaft I show here allows the kickstart to sit too low - it's for a bike that has the gearbox fitted horizontally, rather than at the angle used by Ariel and Brough Superior. The shaft is possibly from a Panther, who used these boxes horizontally in 1929.
The flat will have to move for the new shaft.
This is the flat where the pawl sits, with the axial holes for the pawl pin and the tangential hole for the pawl spring:
These two flats engage with the two plates in the gearbox that stop the pedal travel and disengage the pawl:
This is the bore for the layshaft, with it's bush:
A few dimensions to help us choose the stock for the new shaft:
We see here that the total length of the 'Panther' shaft is 164 mm or thereabouts.
This is the 'Panther' shaft fitted to the bike. This is the excess length - just over 47 mm. That means the total length of the new shaft will be 164 - 47 = 117 mm. Our blank is 150 mm long.
Lastly, here are a couple of pictures from AOMCC member Michael, showing the original arrangement:
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