• I'm also in the process of trying to get to grips with cotter pin cranks.

    This Sheldon Brown page is superb for an overview of removal and installation - https://www.sheldonbrown.com/cotters.html

    The size of the pin depends on the size of the hole on the crank arms, From reading up British cranks are generally 9.5mm and French can be either 9 or 8.5mm - I think.

    It appears that the pins have to be filed before installation of crank arms to ensure that they are a good fit.

    Do you already have Bottom Bracket cup's?

  • I've filed pins to fit cranks before but apparently this isn't a good idea, as hand filing can lead to the misalignment of the crank arm and axle? (and I get that - am no an engineer, just a bodger with a record vice - c.1930 - on a bench likely at least as old as my great-great- grand-parents, and a bunch of rasps.) The ones I 'milled' ended up being a bit sloppy and needed tightening after a most rides (but that might be completely usual? Or I'm an idiot. Likely the latter.) But, the alternative seems to be a pin press which are about £300 or a trip to an LBS who's got one?
    edit
    apologies, boring and not helpful contribution.

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