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Here's the four Dewalt spindles as delivered.
Dewalt part number is 390087-00. |
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I don't need the bearings, spring, or
hammering mechanism. To remove them, I put the spindle in the opening of
my vice without tightening it. I then hit the toothed end of the spindle
sharply with a hammer. Two hits and the parts came off. |
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Here's the separate components of the
spindles. |
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Here's a close up of the spindle without the
extra parts. |
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The sprocket I'm using is a tad bit to big to
fit well on the end of the spindle, so once again I have to half-ass a
solution. I'm going to use this 1/2" brass tube from the hardware
store ($1.25), which will fit perfectly inside the sprocket, and with a
little finessing, will slide over the threads of the spindle. |
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Here's the sprockets. McMaster-Carr part
number 6280K381, Finished Bore Steel Roller Chain Sprocket for #35 chain,
3/8" pitch, 16 teeth, 1/2" bore. |
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I had to knock a little off the threads on
the end of the spindles with an angle grinder, then slide the brass tube
on. |
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By using a hammer, I forced the tube on the
spindle as far as it would slide. It's not coming off any time soon! |
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I trimmed the tube to length. |
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The tube itself isn't at all structural, so I
found some bolts at the hardware store that fit perfectly inside. I cut a
bit of the thread off the end so as much of the smooth part of the shaft
as possible fit into the tube. |
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I slid the sprocket onto the tube... |
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...and test fit the bolt in the tube. Perfect
fit! |
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Again setting the assembly in the vice I used
a hammer to force the sprocket onto the spindle at the proper distance. |
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To hold the bolt in the brass tube I will be
using the same epoxy I did on the wheels. On the first one I found that I
needed to create a channel in the bolt for air to escape, otherwise I
couldn't get the bolt all the way into the tube. I created this channel
with my Dremel and a cutting wheel. |
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I place a little epoxy into the tube (no, the
entire tube is not full). |
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I place some epoxy on the bolt |
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Slide the bolt into the tube. |
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Put the assembly in the vise and tighten
slowly. Extra epoxy will ooze out of the channel I cut. Wipe this off
until it stops oozing. |
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Once the epoxy hardens, cut the bolt a little
longer than needed. |
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Grind the end of the bolt to the final length
with an angle grinder, and finish with a file. |
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Here's the four spindle assemblies with the
bushings. |
