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[Revband]

Just to give reassurance re the life of the gear afterwards, I have done this personally on a Velocette gearbox 15 years ago when a gear was unavailable, this bike is well used and has covered many thousands of miles since without problem. The gear is now available again new but I see no reason to change it.they are a lot harder than you seem to think.

[OldBoy67]

Thanks for the reassurance guys.

Will have a go when I've laid hamns on a suitable grinder. Don't have anything really suitable in my workshop at the moment.

[Revband]

Best to go carefully and try not to overheat the metal slow and steady with cooling time between short cuts. It's easy really,