I have a 1978 Honda XL175 I want to get running again. The Kick start shaft
is broken, a common problem on this bike. Replacements are hard to find and
usually $400 or more. Maybe I can make a few and sell a few. I am wondering
if I can use 4130 steel that is pre hardened to Rockwell C32 and has
135,000 psi tensile strength. Or maybe just take a grade 8 bolt and machine
it. or maybe even a metric grade 12.9 bolt which should be even stronger.
Anyway I am wondering how the splines were made on the original. I could
use the E head, (shaper) on my bridgeport and a rotary table. Do you think
this is a good idea?

Shaft_Model <https://photos.app.goo.gl/EYmLjw9DaPVWnNhj6>
Spline <https://photos.app.goo.gl/1aAY377gQqVcM7q57>
John Figie

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