Removing the cast sleeve was a bit of a challenge and I used a combination of a piercing saw, a wood chisel and old files dipped in talc. This did remove the sleeve but it was hard work and left the stub slightly oversized and not remotely round.

I decided to make a tool to cut the stub into a regular round shape. I started with a length of steel round bar which I had recovered from an old printer fuser unit that I had replaced. I salvaged all the useful parts which included the bar, several springs and a number of screws. I am not sure what type of steel it is but it’s probably the most free machining steel that have used to date.

I cut off a short length and faced off the end. Then I drilled a 3.2mm hole in the end. Once drilled I then took it over to the mill where I secured the length of bar in a square collet block. Finally using a bit of trial and error I cut teeth into the rim. The series of photos below show some of the milling process. I had already took a small cut to establish where the teeth would be before thinking to take photos.

The opposite end of the rod had a stub turned on it (which it located in the printer). This allowed it to be gripped with ease in a pin vice.

It made remarkably short work of truing up the misshapen end of the casting.

The next job is to test fit them to the footplate and see if I have resolved the problem.