First of all many many thanks to everyone on this forum for the brilliant work.
I had picked up an old TLD 5 a while back to use as a spare real, unfortunately it had very tired gears, I was close to stripping it for spares when I realised that the Charter Special main gear is very similar, turns out the only difference is the shaft diameter.
TLD 5 shaft 7.31mm diameter
Charter shaft 7.93mm diameter
I decided on hand reaming the TLD 5 right hand side plate bearing, easiest option for me as I have limited machine shop access at the moment.
5/16" adjustable hand reamer acquired, I started reaming the bearing opening out the diameter until a perfect fit was attained, using a little oil to help with cutting.
(http://i1368.photobucket.com/albums/ag194/braz_campbell/43bfd88c-8231-421a-8292-d71cbf1e7b4e_zpscl9xb67y.jpg) (http://s1368.photobucket.com/user/braz_campbell/media/43bfd88c-8231-421a-8292-d71cbf1e7b4e_zpscl9xb67y.jpg.html)
The reel was rebuilt using a new Charter Special main gear (TLD0008) and a new pinion gear (TLD0029), added new bearings throughout, I also added a new carbon fibre drag and a TLD 15 longer handle (TLD0206).
(http://i1368.photobucket.com/albums/ag194/braz_campbell/c4fe4831-12ce-4335-be10-29455268e82c_zpscpzdpxka.jpg) (http://s1368.photobucket.com/user/braz_campbell/media/c4fe4831-12ce-4335-be10-29455268e82c_zpscpzdpxka.jpg.html)
I now have a perfectly serviceable TLD 5 that will last for many years to come, great for a reel that was almost sent to the scrap heap.
(http://i1368.photobucket.com/albums/ag194/braz_campbell/475ee14b-74ec-4fbe-a8cc-705c15ee94a0_zpssuapwcsb.jpg) (http://s1368.photobucket.com/user/braz_campbell/media/475ee14b-74ec-4fbe-a8cc-705c15ee94a0_zpssuapwcsb.jpg.html)
(http://i1368.photobucket.com/albums/ag194/braz_campbell/d10bc44a-cf09-41d1-ac60-30d6142c25ab_zps9tty9jv9.jpg) (http://s1368.photobucket.com/user/braz_campbell/media/d10bc44a-cf09-41d1-ac60-30d6142c25ab_zps9tty9jv9.jpg.html)
Wow. I presume that the pinion gear in the TLD5 was larger.
Great work braz.
I have a much-loved 5 which will get this treatment when the time comes.
Cheers!
Interesting...Maybe now there's no tolerances between the gears...perfect fit, like a glove.