This is my first post although I have often ended up in these forums when searching for advice.

I've had a Flexispeed Mk1 for a few years but have recently bought a Flexispeed Mk2 to restore and replace it. The restoration has now started and the lathe is now stripped down except the headstock. I am having trouble removing the spindle.

The starting point is the large gear is a very tight fit on the spindle, whilst the pulley and attached smaller gear are a freely rotating fit. Applying some tapping to the end of the worm (left of headstock) whilst holding that large gear to avoid headstock damage, moves the spindle to the point that the large gear is no longer tight on the spindle and will rotate: this step is quite easy. But if I continue with this tapping by the time the end of the spindle worm is just about flush with the headstock bearing I find the pulley is then VERY tight on the spindle.

Questions are how to proceed and have a missed something here meaning I am going about this the wrong way? Should I support the pulley somehow (to avoid damage to the right hand side of the headstock) and continue knocking the spindle through?

It seems to me this has to have been assembled in the first place by the reverse of the procedure I'm trying to follow now so I'm a bit mystified as to why it's so very tight although it seems to me there must be a section on the spindle that is slightly larger diameter.

As I know there have been various threads related to Flexispeed lathes in these forums I am hoping someone can offer some advice on this particular problem. Any help would be greatly appreciated.

Andy

Thanks for the replies. I think Neil was spot on with his theory of a burr.

When I started on this yesterday the large gear would only rotate about 5 degrees (with the grub screw out of course). I then went through the spindle tapping process, then when the pulley appeared stuck became cautious, tapped it back to the start position and gave up to seek advice.

Returning to it today I found the gear rotated more easily by about 30 degrees and after a few "wiggles" things started to move quite freely and the spindle came out. No sign of corrosion but it looks like the gear grub screw had been tightened right on the edge of the slot raising a burr. I reckon my tapping yesterday had started to remove that burr.

Had I carried on yesterday I would have succeeded but "better safe than sorry" I reckon 😊. Thanks

Andy