Hi Hooksey, Now we have your thread in the right place, I'll try and answer some of your questions.... grin

(1) Firstly, it is good to know how the "captive cotter pin" system actually works, in order to release it and remove the inner clutch half. Here is an illustration:
[Linked Image]
As you can see, you just undo the nut and gently tap the pin down until it releases from the shaft....Just get some Penetrene down the pin area... and down the shaft from the centre of thrust bearing...replace the nut and re-tighten to pull it back up until it re-engages the shaft again...and the then tap it back down gently...then.... with a 3 leg puller gently try to remove the clutch half. wink

(2) Firstly remove the self aligning bearing housing from the machine...remove the nut from the engine shaft....try and get some Penetrene down the keyway...leave it for a while to soak in....then use the 3 leg puller to remove the 12 tooth motor sprocket and then remove the engine shaft. wink

(3) Your quite correct there Hooksey, you send the grass box, mower chassis ( completely stripped of all parts), the chain case, and handle bar centre cover to the sandblasters. wink
I cannot answer your other questions as I live in NSW, you need to look in your 'Yellow Pages' and let your fingers do the walking. lol

(4) Please do NOT attempt to remove the bedknife (bottom blade) from the soleplate...Just get the whole thing(as it is) sandblasted with your other components and take it complete, with the cylinder reel, to the engineer who will do the sharpening for you...He will remove the bedknife for you (he has the expertise) and can supply a new bedknife and screws for you, if deemed necessary.

(5) This is a hard one to answer, without seeing the repair in person...If it has been done professionally, It will be fine...However, if (as Grumpy says) it is a 'previous tenants improvement'....it may need attention. wink

(6) The trick is...plenty of Penetrene down the centre hole....let it soak in well....and screw it off anti-clockwise. wink
Please let us know how you get on....Best of luck with it..
cheers

Please do not PM me asking for support. Please post your questions in the appropriate forums, as the replies it may receive may help all members, not just the individual member.
Kindest Regards, Darryl grin