Congratulations Bill the most important part is in the end you overcame the problem, and won the battle saving an otherwise good piece of equipment from the scrap yard. For some strange reason when I run into a problem like yours I can't stop working on it untill I have either solved the problem or ruined it beyond all chance of repair. But since it is already ruined the only chance you have is to make it better
Sometimes the simplest solutions are the ones that we don't even think about especially when we already have the "proper tools for the job", I.E. gearpuller, such as using a sawsall or side grinder with a cut off wheel or even a circular saw with a metal cutting abrasive wheel to cut a slot completely through the coupler parallel to the shaft. Once you get the slot cut you can drive in a cold chisel as a wedge to spread the diameter of the coupling alowing the penetrating oil to reach the rust. It is time consuming but isn't hard work. This only works of course if you don't mind destroying the origional part. I have used this method several times, it always works.
I once used a circular saw to cut lengths of 6 x 6 x 1/2 angle iron to build a hitch for my motor home. My torch was out of gas, my grinder was burned up I didn't own a chop saw and I wanted to get it done without making a trip into town. Wow that was a noisy process
The maintenance pipe fitters at Dow chemical recomend something called PB-Blaster for rusted parts. It seems to actually disolve rust if you can get it to it.
Of course there is great satisfaction to be had by just beating it into submission like you did, once again congratulations.you won!!!!
Cutting a slot is a great idea, I hadn't thought of that. Very creative, thanks.
As for saving something from the landfill, my wife tells me I do too much of this. Although if something has to be recycled, a rotary mower is probably a good candidate, it seems to be 95% steel.
I am glad I got it working though. I cut the pasture yesterday and it seemed to work fine, although I must admit I STILL (even with lots of advice herein) don't know how to adjust the new slip clutch just right.
I think I'm going to take the slip clutch off over the winter and cover the mower spindle, might cut down on the rust.
BTW, I did use PB Blaster!
