Sprocket Enlargment Help

Discussion in 'Motorized Bicycle General Discussion' started by weekend-fun, Apr 24, 2010.

  1. weekend-fun

    weekend-fun New Member

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    hey guys,
    as you might of seen on the higgins, it has a weird hub. turns out its just barley to big for the sprocket to fit on it. Ive tried sanding it w/ a sanding bit, no luck tho. Does anyone else have any tips on how to enlarge the sprocket
    thanks
    Sam
     
  2. Ted

    Ted New Member

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    Somewhere on this forum there's a solution to your problem, it involved cutting off the top of the dust seal allowing the sprocket to seat, I'm new here and have no idea how one would search for it but I know it's here complete with pic's on how and what to do.
     
  3. Bikeguy Joe

    Bikeguy Joe Godfather of Motorized Bicycles

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    #3 Bikeguy Joe, Apr 24, 2010
    Last edited: Apr 24, 2010
  4. silverbear

    silverbear The Boy Who Never Grew Up

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    Thanks for tip! Why didn't didn't I think of that? I sure had plenty of time to with sitting there filing away with a chainsaw file forever and a day. I've done several of them, the last with the dremel tool (slowly) and your way makes lots more sense. Not only is it easier, but there is also less chance of enlarging the hole out of round (off center). Good one. Should be a sticky.
    SB
     
  5. Gator Wrestler

    Gator Wrestler New Member

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    I have enlarged a couple of sprocket holes using a pair of round files. I chucked one in a power drill and held the other by hand. With the drill at full power I placed the sprocket hole on to the spinning file. The sprocket will spin. The other round file is used at the bottom of the hole. While the drill with file is spinning the sprocket from the top use the other file to file the bottom of the hole. It's not easy but worked fine for me. This removes metal at a rather slow pace allowing you to stop often and get the hole just big enough. This aids in proper alignment.
     
  6. crzyolphart

    crzyolphart New Member

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    I had the same problem with mine. I used a Dremel with barrel sanding tubes.
    The Dremel spins clockwise. Twirl the barrel sander COUNTERCLOCKWISE
    in the hole checking periodically with calipers. Start with a coarse grit.
    finish the last .005 to .010 with a fine grit. I fitted mine in about 20
    minutes to +.005 and true within .002 TIR..flg.
     
  7. Venice Motor Bikes

    Venice Motor Bikes Custom Builder / Dealer/Los Angeles

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    If you have the tools, you can use a drill press & a hole saw, or a cutting torch & a 'rat tail' file.
     
  8. K.i.p

    K.i.p New Member

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    Support onshore manufacturing and take it to your local machine shop so that it's bored correctly and dead-nuts for concentricity. Knocked mine out in about five minutes. Know what size you want and do a little shmoozing. It'll cost next to nothing. I know from whence I speak.
     
  9. mountain80

    mountain80 New Member

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    I agree machinist ARE you're friends.
     
  10. Gator Wrestler

    Gator Wrestler New Member

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    In my case only a small amount of metal needed removal. It was quick to do it myself rather then go into Hammond and back which takes 20min each way. Living out in the sticks has some disadvantages, but overall I like the peace and quiet.
     

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