knew it was too good to last. I was pleasantly surprised to find the first cut of the year I did a couple of weeks back was really easy - no damp grass clogging the mower, or soft ground for it to sink into this time.
Last week I was three quarters of the way through and the mower suddenly stopped cutting. Thought at first I had lost a drive belt, but then I spotted a 5" diameter pulley laying on the lawn. Investigation revealed that the main drive pulley on the top of a blade shaft had dropped off, and its quite substantial 24mm flanged nut was nowhere to be found.
The centre hole of the pulley was somewhat enlarged and chewed up, so it had obviously been working its way lose for a bit.
I collected the new nut and pulley I had ordered from the mower place on Saturday, that was when closer inspection showed that the pulley had a splined centre hole, and the top of the shaft no longer had many splines! I did consider just cutting down the spacer below the pulley to drop it onto a bit of the shaft that was still splined, but in the end decided that might run the belt too close to the top of the cutter deck (especially given the price they charge for belts is daylight rubbery!). So figuring there was not much to lose (other than another week ordering a new shaft), I decided to run a bead of weld around the top of the shaft between the worn splined bit and the threaded section on top. Then I slapped the shaft in my antique "hobby" lathe and turned the weld down to match the major diameter of the remaining splines. All it then took was an hour titting about with a mini drill (must get a proper dremmel!) and a couple of mini grinding wheels to hack something resembling splines back into the new metal. The result was not that pretty, but it seemed to do the job when reassembled and the nut done up gorilla tight! Even sharpened the blades while I had them handy ;-)