Cotter Pin Press by George Hagerty
. Needing to access my gearbox for inspection, I began the long suffering duel against a recalcitrant hand shifter cotter pin; soaking in oils, brass drift pin and hammering on loosened nut run up to end of pin all bore little movement over 2 days. Obviously not wanting to bung the threaded end I was at a stop. Understanding in advance from Duane Ausherman's incredible BMW website (http://w6rec.com/duane/bmw/index.htm) what the cotter pin looked like (NOT what we usually think of as a "cotter pin" - aka a 'split pin') and how it behaved (slight deformation against shaft grove over time) I thought there must be a way to press the pin out. And then it hit me: reaching back into the files of my mind I remembered building pedal bikes in my teens and that the lower crank set and pedal have the very same type cotter pin affixing the crank set (and opposing pedal arm) to the bottom bracket drive assembly. These get stuck in the same way - press fit, flat faces into slots in axles with little room to swing a mallet and get good strikes for removal. A quick search on the internet finds a coveted (by pedal bike enthusiasts) albeit no longer produced "cotter pin press" by Park Tools on Ebay for upwards of $60. So, borrowing from the pedal bike world I decide to make my own cotter pin press. Cost: $5. Time: 10min. Operation: Priceless.
1. Purchase a minimum 1 1/4" throat "top beam clamp" from a hardware supply store.
Pedal Bike Cotter-pin press = Top Flange Beam Clamp
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