Almost one third of the crankshaft has broken away just where the woodruft keyway is, and I think that it is due
to the quite loose fit of the sprockets on the crankshaft. All my cranks are the same OD and all my sprokets are
the same ID, so they must be made that way. And they are all too loose a fit!
So now I have a problem. How do I go forward from here. I need to fix the cranks. I have had then tested for hardness and it seems that the Villiers cranks are hard all the way through.
Idea 1 is to make a new shaft and fit it but the Villiers cranks are make as one unit to that means annealing the crank and machining out the shaft and maching a hole and keyway, making a new shaft slightly oversize where the sprockets go so that they are a tough push fit not a loose fit.
Idea 2 is to repair the shaft as best I can by weld or metal spray and cut a new shallow key on the opposite site to the woodruft key. Buy a sprocket blank and machine the boss to be a tight or interferance fit with the repaired shaft
So, Dear Reader, if you have the experience or skill to tell me what to do, I would like to hear from you
