[Stephen Kowski]

I'm sure someone has probably mentioned this and I missed, but that's ok I'll jump on this dog pile nonetheless....

A very reliable method that has worked in the past for me is using pins in the hubs....buy a standard sized steel pin (one size should work for many, many applications so this is a one time investment you can use again and again)

this can be done pretty easily with a vice and a standard table top drill press

So for example if I had a quarter inch pin I would buy a bit two steps down on your handy ansi size charts (in this case a C drill bit will work; .2420) drill the .2420 hole through the hub (perpendicular to the shaft, not through the face of the gear) and then drill through the shaft where you want the hub to sit

repeat the same process with these new drilled holes, but this time use a reamer that is only one step down from 1/4" (in this case a D reamer; .2460)

now slide your gear on your shaft start the pin in the hole on the hub and use a press (or if you dont have access to a press, a hammer will work, notice I said it would work but may not be ideal) to force the pin down through the hub and shaft, stop once you are all the way through the hub

this is a very good connection; if it something you will be changing often I wouldn't try it, but if you just want something that you want to be permanent and you don't want to even think about it breakin/coming loose

Oh and if something somehow shears (has yet to happen to me)....knock/drill back out the pin and just go to a larger pin size using the same method.....

gl