Back home after a few days away fitting a new front door and frame at my daughter's house in Kent, I find a few minutes to move the kickstart shaft project along a little bit.
When I left a few days ago I had the shaft set up in the pillar drill just waiting for final adjustment and the fitting of a centre drill to start the hole for the pawl.
That done, we move on to the 9/32" hole on the outside of the shaft. I have discovered that the pin is retained in place by the low gear pinion and cannot come out in service. I bought a pair of long series drills for this job and it makes it a little easier to set the work up on the pillar drill. We go right the way through both sides with this one:
We follow the 9/32" with a 5/16" drill which only goes through the inside web. I'm pleased that the pin fits very well in these two holes and with a little fettling (the pawl was rather ragged) the pawl goes in as well.
I'm a bit concerned by the shape of the pawl where it engages the pinion as the surface, perhaps not surprisingly, is rather worn. A further problem is that the cam which pushes the pawl back into place actually jams the shaft. This is due to the lack of wear in the new shaft I think since dimensionally it is identical to the old one.
Working on the pawl a little to square it up and refine the edges sorts out the problem and we have a pawl that goes nicely into the retracted position:
The video shows it working in both positions:
A dose of heat and a pot of case hardening compound will give us a pawl that fits and has sharp edges giving it plenty of life. We'll have to see if it still works with the bush in place - that might require a bit more fettling, so we will leave the case hardening until that is done.
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