Searched the forum, but could not find the specs. I plan to Mic. the shaft at the bearing surface, and then Ream/Hone to size. What would be the the minimum clearance to use here, 0.002 + or - ?
John,where the shaft is not worn it is 3/4" , when you ream the bushing to allow the shaft to pass through, the worn section on the shaft will still allow slop.
If you machine the shaft down, then part of the taper on which the pitman arm fits will be machined off too, not a good option. The best answer is a new shaft or at least one showing minimal wear.
Hope this helps.
Allan from down under.
Allan has great points that should be considered.
Another option would be to have the worn portion of the shaft Flame Sprayed to build up the lost metal. Then machine to original 3/4" and problem solved. Since there is not a lot of rotational speed or radial thrust, the flame spray will last as long as the original.
I had a shaft spray welded (as Terry mentioned) and it worked great. Built it up to standard with no warping. Dave