Generator shaft repair

[JM 35 Sedan]

I believe B-O-B has the best idea. Knurl the worn section of the shaft to uniformly raise that area enough to give something close to the original press fit for the ball bearing. We used a controlled staking operation (4 stakes placed symmetrically around the shaft at a controlled height) to hold lamination stacks on armature shafts (high volume universal electric motor manufacturing). These same stakes did not work that well to hold commutators and ball bearings in place because they caused stress concentrations in the areas where they contacted the commutator and ball bearing ID's. A knurl would spread the press fit load more evenly around the ID of these same parts. If you know someone who has a lathe and a knurling tool he could fix that shaft in no time for you. A light coating of Loctite on the knurl prior to pressing the bearing in place is also a good suggestion.