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an update - pictures coming later
1-I got the shaft hard chromed and ground to size - seemed to come out fine - $200 - fits with about 0.001" clearance in the trans.
2-I pressed the high temp. plastic bushings into the fork and a very fine crack showed up, very likley from too much press fit interference - I was pushing it by 0.002". I have more bushings - the OD can be sanded down, I'll do that and try again. Hopefully the ID will not open up too much. I feel this is an issue with plasitc bushings - the tolerance planning before and after press in can be a bit tricky. Also it is not recommended to machine the ID of the bushing. Given that and the shaft needs to match the trans and you don't really want to machine the fork, this provides something of a design corner you end up in. The IGUS catalog info. doesn't provide good detail on this in my opinion. I feel they should have very clear algorithms you could use to estimate the final ID. Also, since the parts are plastic the final as made dimensions have a rather wide tolerance going by the book.
3-ordered and recieved shaft seals 22x16 that should press in - this will seal the shaft to the fork on the side that sees the clutch dust - I haven't seen these yet, a buddy picked them up.
That's about it for now.
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