...what's the best way to remove the rivets from the clutch shaft and the low pedal shaft?
I personally like to dremel the flattened heads of the pins off. Then just a punch and a BFH. The pins are 1/4" unless they've been replaced with larger.
I do the same thing as Seth.
Grind off the head and drive out the rest with a punch.
Just grind one end flat, make punch on the flat side and drill the pins with a 3mm drill all the way. Take a punch of the right seize and drive the pin out..
Just the way I do it.
By drilling the hole you take away the stress in the pin.
Steve, I use a modified Andre approach. Rather than drill all the way through, I go about three parts through. Then I use a pin punch in the hole. The blank end gives a land on which the punch pushes, the hole is a guide for the punch, and it stops you from mis-hitting the end of the rivet and burring it over again. On really stubborn rivets, I upsize the drill until it just cuts down the side of the rivet. That makes the job really easy.
It still pays to use a heavy drift under the shaft/fitting to take the pounding of you selected driver.
Hope this helps.
Allan's method has always worked for me the best- don't drill all the way through- that way the punch will pull the old rivet out rather than pushing it out. I always put a steel block under the cross shaft to support it rather than letting the hogs head support the shaft.
Aluminum or iron hogshead? Makes a big difference. The iron hogsheads are tough, and can take a bit of pounding. The aluminum ones can break easily with just a mild hammering if the shaft is not separately supported.
Otherwise, how Dan McE and others have all said.
For me, better to just cut off the old shaft near the pedal, and then junk the rest of the low speed shaft and notch.
When trying to drill out the rivet in the notch, with the low pedal stuck in the hogshead, the job is really tough.
Besides, the notch is worn, that's why you are removing it, and a new shaft is much better than the old.
So SawsAll the low speed shaft near the pedal support on the hogshead, and remove pedal with stub. Take to workbench and grind rivet flat, centerpunch, drill partway into the rivet, and drive it out with a punch. Fun that way
SawsAll cut away of old low speed shaft, drilled out rivet in stub of pedal.
Slip back in the new shaft on the low pedal, and re-rived a new notch on the new shaft.
I'm glad I finally managed to drive the pins out of the clutch shaft. You can buy new pedal shafts, but not that one.