Making the shaft line assembly

 I decided to go for alternative 2 where I use a lathe to make the shaft outer diameter same as the weldable bushing inner diameter. To get access to a lathe I registered to a metal forming course were you are allowed to bring you own projects. The bushing originally acquired was quite short so I bought a longer one to be able to make it the desired length.

Below a picture of the main parts, modified winch drum and bushing. The reason why I kept the whole length of the winch drum is that the material was thickest at the end of the drum, so I wanted to use the strongest part of the shaft and take away material only where the wall is the thickest. I also kept about 5mm untouched of the thicker part of shaft to avoid causing a weak point where the drum would break, this is the reason I did not make the lathed area longer. The hole in the drum is for fastening the winch cable, the location is a bit unfortunate.   


The bushing has been cut to desired length and the tread for the stop screw is in the making. 


I was worried about using a stop screw towards the soft aluminum cast so I decided to go for a 6mm tap to lock the winch drum and bushing together.



 To secure the tap in place I made a punch close to the tap end.


The shaft line assembly mounted on the bead roller!





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