[TR] off-topic - fixing damaged electric motor shaft

[Randall]

>  and (assuming that I already had the pulley) turn 
> a bushing to
> make up the difference btween the pulley bore and the now 
> smaller shaft dia.

Just a thought, depending on how bad the damage is : Most hobby shops will
have 1/2" od thin-wall brass tubing for a few $$.  If 15/32" will clean up
your shaft reasonably well, you could probably cut a length of brass to use
for the bushing.

> Without that, you could try to run the motor w/o the pulley and hold a
> file to it (place the file so that the shaft will pull the file *away*
> from you) 

Another way to approach this might be to grind a sharp corner onto the end
of the file, and rig a suitable support so it could be used like a lathe
tool.  I have used this approach (before I got a lathe), and while the
result probably won't be pretty, it might be serviceable.  Take your time
and make very light cuts.

Randall