There is a lot of play between the clutch pedal shaft and its boss. The shaft is .003 under and the boss bore is .004 over, for a total of .007 play. Doesn't sound like much, but it is very noticeable, in feel and in loudness. I know I can replace the shaft, but that only solves half the problem. There is no bushing in the boss, and it is cast-in on the hogshead, so no replacement. So am I just stuck with the .004 play in the boss, or are there any tricks to tighten this all the way up (oversize shafts, brazing and re-boring, divine intervention, etc.)?
Not a problem. If you replace the shaft it will be less clearance. Only potential problem might be an oil leak. Some have fixed that leak by using an O ring. A more likely source of a problem in shifting would be the link between the clutch lever and the pedal. In your picture it is quite worn. You can purchase a new link through the vendors and you can also weld up the hole in the pedal and re-drill it to fit.
I have used over sized shafts or bushings as needed. If you use the over sized shaft you will need to open the cam and pedal holes just a little. They should make an over sized stepped shaft for us guys without a lathe so we don't have to ream out the pedal and cam.
Just need to ream it out and install a bushing.
Sounds like a bushing is the way to go. Thanks, guys.