[I note that Google Groups is still acting weird. It didn't respond to
an attempt to Reply earlier today. But I'll try...]
Thanks, folks, for the help with the jammed cotter. We got it done!
Here's how the (frustrating) process went to the happy ending:
1. Try to whack out pin, no budge, Park tool doesn't budge, pin
mushrooms, heavy hammering with various punches doesn't budge.
2. Saw off both sides of pin, drill out partly with drill-press, drill
thru with smaller bit at outside of hole to avoid spindle. More punch
and chisel attempt, no go.
3. Simultaneously consult with you nice people. : )
4. See Jobst's mention of testing for arm alignment. Arms are aligned
but this concept makes me think that working the arms might loosen the
remaining fragment. I reinstall wheels and stand on arms, with some
bounce, from either side. IT DOES! Fragment falls out.
5. Everything is fine. New pin.
(The only reason I attempted this was to try to ship a very
large-framed bike at optimal low rates. I would now try to avoid
removing old cottered cranks no matter what! This one was on a fresh,
lightly used, clean bike---but still stuck!)
--JP
allbikemag.com