As we get towards the end of the kickstart shaft project, it's time to think about where the lever will sit and where the flat for the cotter needs to be machined. This picture mocks up what it will look like eventually:
The key to success here is to understand the relationship between the mating face of the cotter and the flat on the shaft, all of which combine to determine the position of the lever. The last thing we want to do is to have the lever too vertical or too low in relation to the rest of the machine - worst still that it sits forward of the gearbox!
We'll use the old shaft to understand this relationship.
What you see here is two pictures of the lever, the cotter and the old shaft. I have used a Sharpie to show the relationship between the shaft and the lever.
We can see that the cotter fits in either direction without affecting the relationship between the shaft and the lever.
This next rather blurred picture - it looks like it's focused on the bench top - shows the Sharpie mark against the flat on the old lever and confirms that the flat is perpendicular to the axis of the lever.
We can use this information when we machine the flat on the new shaft. We'll have a look at some of the reference pictures and get a feel for where the lever should be.
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