I was talking to T-Man about how he modified his 7/8 hex axle to accomodate a 1" hub, and it appears he and I both came to a similar methodology for accomplishment. He has videos up that show what he did, me, not so lucky im afraid, no video, but I will try to explain what I was planning to do, and how I prototyped it.
First, the thought was to take a 7/8" round shaft (not hex as I apparently have an aftermarket live axle on my cart) and expand it to fit a 1" hub. Now, it turns out I don't need to do this, as I found out this evening (after finding my calipers) that I have a 1" shaft so it is indeed an aftermarket and I caught a break on this as 1" axle parts are much easier to find then 7/8 hex parts.
Now, I did find myself in a small predicament a while back, when my 6hp Tecumseh was not running well, and I had a functioning 3 hp B&S motor. the Centrifigual Clutch and the engine side of my two Comet TCs, both are 3/4 shaft. So, I went to True Value Hardware and bought a couple 5/8" id and 3/4" od bronze bushings, used a dremel to cut a 1/4 slot in the bushing (full length of the bushing) and slid these two bushings on the shaft alongside the keyway. Now, this won't hold with a standard key for a 5/8 (or 3/4 for that matter) key as there is just not enough key getting into both of the keyways. So, back to TV for a new "taller" key, and a little filing to fit, and there you have it, a way to fit a 3/4" centrifigul clutch to a 5/8 motor shaft. since the clutch has allen head retaining screws (one on the key and one offset about 90 degrees or so) the clutch seems to hold well and has no issues with being out of balance.
One note, you may have to use some emory cloth to take just a smidge off the outside of the bushing so it will fit on without having to pound everything together. Also, I ran a round wire brush on a drill inside the old clutch to remove any corrosion.test fit it all and make sure you can put it on and off without a hammer before committing, cause getting it off if you tap it on becomes a bit of a pain (but a finger type wheel puller will help if you get a little anxious)
You all probably knew how to do this already, and I will take a pic to show how I did it if you want, but it is actually a pretty easy concept, and with the bronze bushing in place, and a taller key, everything feels real solid.
Dave
