Loctite

The loctite might hold it but you do need to take it off again sometime perhaps!

Yes a small, and sharp, cold chisel on the frame mounted male part, it doesn’t have to be perfect. Then pick up some grooves in the footrest by chiselling down the hole, and not remove any metal, whereas a hacksaw cut will take metal away.

If the slack footrest flops around when first tried then add some shim metal sheet of 0.005″ thickness (suggested size to try) around the male boss and hammer the footrest on. Then tighten well, if it is at all slack it will rapidly loosen again.

A method I sucessfully used many years ago on a worn a Honda C90 gearshift shaft spline was to open up the gearlever at the clamping split line and insert dress makers pins into the gap between the worn splines of shaft and lever. After tightening down the gearlever clamp bolt, the prturding pin length was broken off – relatively easy as the pins were hardened. This worked very well, with the only down side being the need to redo the job from scratch if the lever was removed. A lot easier than spitting the engine to replace the shaft & it survived until the bike was sold on some time later.

This might have been a tip from one of the motorcycle magzines of the day, like Motorcycle Mechanics maybe.

Nigel B.

On 5 December 2024 at 15:29 norm norton Said:

The loctite might hold it but you do need to take it off again sometime perhaps!

…..

Heat it up with a small torch

When I made a brake cross shaft for the Ducati, I cut the splines on the Myford.
I used the changegears to index, what I think might gave been 22 splines.
The topslide screw was removed completely, and replaced with a lever arrangement with a pivot on a cross slide T slot, similar to a lever operated tailstock.
That effectively made a small shaper, so I could use a screwcutting tool rotated 90 degrees to cut out the splines.

Make a second splined shaft out of silver steel, and either use it as a broach by tapering & cutting grooves, or use it in a wobble broach

Bill

It looks like the detached piece with the worn male spline has a crack right across the fitting that holds it.

I am tempted to suggest that you have made / make a new spigot and spline, cut the old one off and drill/bore out the remnants and then braze the new one back in place, repairing the crack at the same time. Not a particularly easy job.

Bob

There are plenty of options depending on how professional a job you wanted or how original you wanted to keep it.

I would cut a new spline on some tough steel, then spline the pedal or use the stub to broach the foot pedal and then cut the old spline off and weld on the new piece.

If you didn’t want to cut of the stub you might try making a vee shaped graver and re-cut the splines but the problem is that the footrest has worn quite a lot of material away plus there will be an equal amount worn from the inside of the pedal. If you can relieve the slot some more so that it will clamp up tight on the stub, you might be able to drill and tap it over the end joint for a scotch key.

Or, since the foot rest is obviously fixed in poisition you could just clean it up, braze it on and paint it black. Keep the pinch bolt and no-oe will know.