Weld undersized shaft

[Kram]

You could turn a 0.15mm wall sleeve and split it for the keyway. Joe Pie has a good video on how to turn very thin wall stuff.

With only a mini lathe making a new shaft, keyway would be a pain to do, but plenty have done it on a lathe.

 

[bigduke]

Is it English or metric thread?

20TPI Imperial.

 

[Jan-DIY]

No way to get it done without thermal distortion or machining. This part is to easy to made new as cracking your brain with it.
Just simple thread, keyway and some surfaces.

 

[mike os]

Weld or braze it will distort, and will need machining… so might as well just remake or remachine the flywheel if that’s a simpler part

there is no magic cure

 

[Munkul]

I could do the lathe part easy but don't have a mill to make keyways. Like Brad says, easy job for someone with both lathe and mill and tooling and just as fast as spray/weld repair if not faster tbh.

 

[ronan]

A lot of British singles were hard on their crankshafts, especially if it was something hot like a BSA Goldstar (notorious for having loose mainshafts). There must be someone close to you doing hard chrome ? There is a place near me that does that sort of thing, hydraulic rams, crankshafts etc. I don't think its so expensive, they would chrome the shaft end and cylindrical grind it to the size you need.

Its the way i would go.

Hard Chrome Plating, Centreless Grinding, and Precision Engineering, based in Ashbourne, Meath, Ireland.

Hard Chrome Plating, Centreless Grinding, and Precision Engineering, based in Ashbourne, Meath, Ireland. E&G Manly precision engineering.

manlyengineering.ie

 

[ronan]

Looking at that shaft, i'd make a new one. A bit of en19t or 24t round bar big enough couldn't cost more than a tenner, the most tricky bit would be the woodruff cut, and there is not much to doing that.

 

[zeppelin builder]

4140 be ok not hardened

crankpins iirc en 36 for case hardening
with good core strength

an old halfsfaft off a rwd commercial
or similar

is that a norton shaft

 

[dan.taylor.1]

I could do the lathe part easy but don't have a mill to make keyways. Like Brad says, easy job for someone with both lathe and mill and tooling and just as fast as spray/weld repair if not faster tbh.

I've a mill if you ever need to machine something, you're only up the road a bit.

 

[Rkweld]

Why is it that you cannot braze or weld inside the flywheel and reinstate the woodruff groove? If I was unsure of the shaft material I would not want to put heat into it and potentially give the shaft a weakness to crack along. Something as small as the wrong rad on a crank journal can cause it to crack so I would not want to weld a shaft that is under alot of stress.

 

[Rkweld]

Also have you looked at buying shim steel and brazing that in?

 

[Rkweld]

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