[MetalMan]

I just finished turning the shaft on my KB-45 10XL. Unfortunately it's a bit far from perfect, but it will work. Since I couldn't get my motor apart to chuck the rotor into a lathe, I tried something else. Bascially, all I did was duct tape the motor to my vice (the vice was open less than the diameter of the motor, so the motor was sitting in the vice). There was duct tape between the motor and the vice, to reduce vibration and keep the motor scratch-free.

Then I spooled up the motor to maybe 20% throttle, and took the Dremel to the shaft with a reinforced cutoff wheel. Once the diameter of the shaft got to the right size, I used 100 and then 400 grit sandpaper to smooth it out. The result is that there are a couple very minor dips in the diameter, but I don't think these will affect performance/strength. But now 5mm bore pinions fit, and now my Savage can hopefully break 70mph :).