[simplechamp]

Well, today was a very bad day. The machine shop called and said they drilled the holes in the output shafts but that the hardened cap was too hard and they weren't even able to make a dent in it. I can't see how this is possible. I told them people have drilled/tapped these in their home workshops and they just said "I don't know what they did but we can't do it, it's too hard". I think the are BSing me and just didn't want to do the work for the price they quoted me. When I first talked to the guy he said "I don't think this is as hard as everyone has told you". Yeah right....

So then I go pick everything up thinking "Well at least they drilled the output shaft pin holes" and the holes are drilled too far in on the shafts. The shafts aren't flush with the gear, they stick out past them. I had written 0.229" on my drawing but I haven't measured yet to see if they drilled the wrong distance or if 0.229" is wrong. It's my own fault for not double checking it myself.

At this point I don't even know what to do. Output shafts can be ground down to make them flush, but they might be too short now, and I guess I'll have to try drilling/tapping the hardened cap myself without having access to proper tools. Everything was going so well....

EDIT: I'll post some pictures of the shafts with gears when I get home, maybe you guys can see if I'll still be able to salvage them.