Motor Shaft: Grind Yes or No?

[redshift]

I left a few things out of my first post.

I am running a 9XL with an RCM pinion, setscrew out. To get full mesh the setscrew is out as far as I can go. In other words I can't grind it, the setscrew will be on the edge of forcing the pinion off, so in my case I'm hoping there is enough bite without grinding it, only using Loctite.

It makes sense for balance reasons to do it, usually there is extra setscrew length that will be compensated for by removing some shaft material.

And what are your methods?

I'm pretty good with a dremel, but for some reason I can never do it cleanly on a motor shaft, even with the shaft held steady.

The cleanest way is using a surface grinder, but most people don't have access.

So what are your various tricks for doing it- cutoff wheel, round stone, etc.?