The other thing that failed in Dave Leonard turbo application
was the input shaft for the second time. When it happened
the first time I made a few calculation and recommended
two pins instead of only one. Everybody ignored me :)

Here is a two pin version I just completed for Michael Hart
in Saipan. The bolt is 5/16th AN which are fairly consistent on diameter
and are slightly tapered. The AN bolt was used as the 2nd pin and press
fitted. The hole was reamed to .3100.

An MS bolt is .3090 or .001 under size so a press fit would be a problem.

In any event the pins are staked in and the 5/16th pin is locked in by the
thrust bearing race.

The spline shaft and the sun gear are surface hardened
so you will need a solid carbide drill and perhaps a rotary
grinder to modify the sun gear. We tried cutting the sun gear
down where the thrust bearings seat and failed so we had it
ground down. Note that the unused gear teeth are removed.


Paul Lamar

--
I would also recommend using red or green loctite.  The green
was used as the only locking device on AMC transfer case
shaft, if my memory of conversation with Loctite salesman some
30+ years ago is accurate.  Heat to about 350 f for dis-assembly.

Dan F