I make a flat spot for most of the shaft, but I leave the end bigger, just in case the setscrew gets loose. That way the pinion can't go flying off
That's a pretty darn good idea Finnster! I know I recently had a pinion fly off on me... didn't wait long enough for lock tight to harden and/or I didn't tighten th set screw enough.
“The modern astrophysical concept that ascribes the sun’s energy to thermonuclear reactions deep in the solar interior is contradicted by nearly every observable aspect of the sun.” —Ralph E. Juergens