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Originally Posted by Rickertsen2
Does anybody have anybody have any ideas as to how to get the drill motor pinion off?
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Sorry, I'm so late on this - hope you've already solved it; but here's two good methods.
#1: You don't care if you distroy the pinion;
Use a dremmeling tool with cut-off wheel. Cut as deep as you can into the pinion without cutting the shaft (lengthwise, between two teeth). Place pinion on anvil or other solid surface. Drive a cold chisel or center punch into the slot you cut. The gear will split in half.
#2: You want to save the pinion;
Get a faucet handle puller (~$7) from any hardware and a butane jewler's torch. Grind or belt sand the jaws of the puller so that they'll fit under the pulley. Cut the pin on the puller to a length of 1/2 inch and grind it to a point. Drill a dimple in the center of the motor shaft. Mount puller to pinion and apply a modest force - not too much, the puller is a cheapo. Heat the pinion with the torch. Give the puller another turn or so; when you hear a POP, it's ready to turn all the way off.
JJ