Magneto drive gear

In the previous post, I had just purchased an EMag Air brand PMag  Model 114 electronic ignition to replace my left side Slick brand magneto ignition model 4370. To run the internal alternator and provide a position sensor, you need to take the gear drive off the magneto and put it on the PMag.

My friend Kelly from work came over to give me a hand. He grew up around airplanes but never got around to flying, he built a show winning '44 ford pickup that he inherited from his grandad. He knows his way around a machine shop and engine better than I do so he was a helpful hand. So, off came the old gear drive, which required a gear puller and a busted finger (sorry Kelly!) 

Here's the PMag with the gear drive installed. It was a tough balancing act to torque the castle nut to the correct torque value (120 - 150 in-lbs) but still have the hole line up for the cotter pin. The PMag came with 2 washers so we ended up just using one so we could expose more threads and allow the cotter pin to line up with castle nut.

The final step was attaching the cotter pin. Turns out it wasn't as easy as I thought to crimp that down but prevent it from protruding past the gear so it won't scrape up the engine case when it's bolted in the accessory case. Anyway, all done! Just need to install it, and of course I forgot to bring the mounting nuts from home. But it should be easy to just pop it in the next time.