On 1/22/2018 1:07 AM, Puckdropper wrote:

....[snip for brevity]... dpb

Regarding the motor gear: the other option you have is to grind off the
gear teeth and start with a smooth shaft. It'd be much easier to cut a
gear with that bore than it would to cut a gear on that shaft.
Especially if we're talking about filling in new metal, where there's
very little chance of things being a consistent hardness.

Puckdropper

Indeed; it would be teeny to cut all the teeth down but to make
concentric and round wouldn't be too hard. Oh, but then there would be
very little room left between new ID and existing OD to match existing
size to match up with the driven...but, I suppose, still at least in
realm of possible...

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