On 10/24/22 9:28 AM, John Figie wrote:
I have a 1978 Honda XL175 I want to get running again. The Kick start shaft
is broken, a common problem on this bike. Replacements are hard to find and
usually $400 or more. Maybe I can make a few and sell a few. I am wondering
if I can use 4130 steel that is pre hardened to Rockwell C32 and has
135,000 psi tensile strength. Or maybe just take a grade 8 bolt and machine
it. or maybe even a metric grade 12.9 bolt which should be even stronger.
Anyway I am wondering how the splines were made on the original. I could
use the E head, (shaper) on my bridgeport and a rotary table. Do you think
this is a good idea?
Shaft_Model <https://photos.app.goo.gl/EYmLjw9DaPVWnNhj6>
Spline <https://photos.app.goo.gl/1aAY377gQqVcM7q57>
John Figie
Those splines appear to be either rotary broached or rolled. Any other
way is going to need a relief cut between the spline and the shoulder.
Grade 8 or 12.9 are about 150,000 PSI, about 30 Rc.
Ed.
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