Sprocket stuck on axle (again)

[Jakebleazard75@gmail.com]

Hey guys, thanks to your advice, I am in the process of installing a brand new t/c for my go kart. Problem is, the nice new sprocket I got won’t move, because the key in it is to big. Any suggestions that only involve very simple hand tools (also, no torch either)? Thanks guys!

 

[HONEYBADGERFTW]

A simple file and elbow grease plus patience and a **** good eye for straight, lol. I’m just saying what I would do if I was in your shoes.

 

[mckutzy]

Howabout some pics... as what was explained in your last post...

 

[Jakebleazard75@gmail.com]

Sorry about that. I should have explained it more clearly. I’m not sure how to put up pictures and I will look how to do that. So, what is happening is the piece of key 1/4” key that I used was slightly to big, and when I put it in the friction keeps the sprocket in place.

 

[mckutzy]

This thread here...
http://www.diygokarts.com/vb/showthread.php?t=737

Friction doesnt hold the key in place... a setscrew does...
The key does need to fit the key way on both parts.. its common to file fit a key to fit...

 

[Jakebleazard75@gmail.com]

This thread here...
http://www.diygokarts.com/vb/showthread.php?t=737

Friction doesnt hold the key in place... a setscrew does...
The key does need to fit the key way on both parts.. its common to file fit a key to fit...

The key is too big, and got hammered in a space it’s to big for. Standby and I will try and post some pics. I tried the grease and file but that won’t work.

 

[Jakebleazard75@gmail.com]

Here they are, the key is there, but very hard to see.

 

[mckutzy]

File fit the key till it slips in the keyway profile of both the shaft and hub...
File the shaft keyway to remove the sharp edges for which it is probably hung up on...

If it stuck in the shaft. Use a punch to drift it out...
File off the marks, carry on till it fits right...

 

[HONEYBADGERFTW]

Can you take the axle off, stand it on end on a piece of wood (to protect threaded end), and tap the sprocket down off the key (using rubber mallet, or a small block of wood held against sprocket and hit with hammer)? Might have to use vise grips (again, use thin piece of rubber or cloth between grips and key/shaft to prevent tooling marks on metal) to secure key to axle to prevent it from sliding with the sprocket.

 

[Jakebleazard75@gmail.com]

Thanks for your help HONEYBAGERFTW and mckutzy. I can’t take the axle off without removing the sprocket. I might have to go to my friends who have have a real torch or just buy one. I hate to burn off the nice new powder coat on it..... oh well. In the picture, you will see that a piece of tubing prevents me from removing the axle.

 

[txluke]

Easy fix. Get some long bolts that will fit in the holes of the sprocket. I see you already have one sticking out. If they are not long enough get some blocks of wood to put between the frame and the bolts. With a nut on the bolt you will tighten them and have them push against the wood. Switch from one bolt to the other and it should push it off.

 

[Jakebleazard75@gmail.com]

Thanks for the idea, I actually have a flywheel puller, but no bolts long enough, and that's the wrong direction that it needs to be pulled. If anyone has a free propane torch, that would be appreciated.

 

[txluke]

It shouldn't matter what direction you move it. Just try to get it off the key and then you can get the key out and do whatever you need.

 

[mckutzy]

Heres a cool torch... its a start...
https://www.harborfreight.com/propane-torch-with-three-burners-91899.html

Howabout a few pics not so zoomed in....

 

[machinist@large]

The key is too big, and got hammered in a space it’s to big for. Standby and I will try and post some pics. I tried the grease and file but that won’t work.

Since there aren't any parts on a kart that require an interference fit like that, that's a problem. How close to the end of the shaft is the key? At this point as I'm seeing it, you have two options for trying to get the key out.

Method#1 (Preferred) If you can get a good grip on the key with a set of vicegrips WITH THE GRIP'S PARALLEL WITH THE SHAFT you might be able to tap it out by tapping on the end of the vicegrips. If that doesn't work, you're kind of left with the next one.

Method#2 (Definitely less preferred) You'll need a 3/16" drill bit long enough to get from the end of the shaft to the opposite end of the key in question (don't forget to add the extra length you'll need to hang onto the bit in the drillchuck). Then comes the sucky part: drilling thru the key without veering off course. If that's not an option, you're basically left with cutting the end of the shaft off and replacing the shaft w/ a new one. Sorry....

 

[JTSpeedDemon]

 

[txluke]

Wouldn't it be better to cut the sprocket parallel to the key? He would just have to pry it open a bit and slide it off. I think a sprocket costs less than a new axle. If he cuts it in line with the key he has a good chance of never hitting axle with the blade.

 

[machinist@large]

Wouldn't it be better to cut the sprocket parallel to the key? He would just have to pry it open a bit and slide it off. I think a sprocket costs less than a new axle. If he cuts it in line with the key he has a good chance of never hitting axle with the blade.

I was under the impression that he was more worried about the sprocket. And just going by the photo, I can't tell if the sprocket detaches from the hub itself. And I can't tell if the sprocket is mounted to the part on the left where the key is jammed or if it's attached to the (disk?) to the right.

As for cutting the part hung up on the key, for some reason I totally forget about something in the Dremmel class ( the smallest cut off disk I've used the last couple of years was a 4 1/2"). Either way, a Dremmel could slit the problem area enough to release the tension; and as long as he doesn't go full on Gonzo cutting it, the slit part would still be reuseable with just a couple of really good hose clamps to reclamp it.

I definitely have to much on my mind when I miss something that basic.......

 

[Jakebleazard75@gmail.com]

Thank you for your help everyone. I will try the vise grip thing, and if I can figure out how to do it, drilling the key out. I don't have any money to spend on anything until I can find a job to do. Thanks guys!

 

[Jakebleazard75@gmail.com]

Hey guys, tried all of your ideas that I could. I'm thinking about borrowing a air hammer of oxy-acetylene torch at this point.