I bored them on a drill press.
Mount the pinion in the chuck and a 5/32nds drill bit in the vice. Works for gears 18teeth steel pinions and up. Anything below that and the pinion will deform when tightening the set screw. 5/32nds is about 3.9mm, but that .1 mm difference is about how much error you'll have from this process.
To key the shaft on the XXL (because it is unkeyed) take a dremel and etch a tiny ding in the case hardened shaft, just enough to mate with the set screw, and no larger. If the color of the shaft changes, you should not cut any deeper and may have already etched too far.
Quote:
Originally Posted by pasan
I just read up on the XXL 1800... the shaft is 4MM? Where do you find pinions with a 4mm bore?
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