How tight should the Bull gear be

There is no freaking way you are going to push that gear against a 0.010 interference. Calipers are not a precision measuring device.

I can't answer for yours, but my bull gear just slipped on (south bend 9 model a). I think polishing the bushing might be the trick. It should not be loose, but should not require a press to release or insert.

Do you have a set of telescopic gages you can use to check the ID of the gear? The flats of your calipers may be preventing a good measurement. I have a hard time believing there was .01 difference between gear and shaft, as I don't think it could be assembled at the factory that way. It is keyed, and any gear I've ever seen that had a key I was able to remove with a mallet and a couple of pry bars, and installation was a few light taps with the mallet.

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I finally got it on, With the press. If I have to take it apart again, I will be sending it to someone to have it turned just a little, But since I was wanting it done before I have to do some other things for the next few weeks. and will not really be able to get into the shop, or anywhere else to get it turned a little decided to finish pressing it in.
I had cleaned and frozen the spindle, then using emery cloth worked on the inside of the bull gear. To the point that the spindle would start into it. Figured I would use a mallet to tape it in the rest of the way. Once I got it started, then it did not budge any more, Even with a hammer and block of wood. So took it over to the press and finished pushing it in.

Again if I have to take it apart again it I will send it or take it to someone else shop to get it turned to fit properly.
Again thanks for all the information.

Ken

At least you got it back together. You could always use a segmented belt if the need arose.

Planning on that have one of the link belts but may want to replace with a new one. Unless the bearings or the seals go out again it should be a long time before having to do this again. Somone else will prob have it by then if I did a good job.

My first lathe was a Taiwanese 1236. They're a good starter lathe, but the fit and finish on them leave something to be desired. It's been a long time but I seem to recall that I had to mill something in the headstock to make the back gear fully engage. So it's not hard to believe that the fit on your bull gear isn't what it should be.