Thanks, folks, for the help with the jammed cotter.
Here's how the (frustrating) process went to the happy ending:
1. Try to whack out pin, pin mushrooms, no budge, Park tool doesn't budge, heavy hammering with various punches doesn't budge. 2. Saw off both sides of pin, drill out partly with drill-press, drill thru with smaller bit to outside of spindle. More punch and chisel try, no go. 3. Consult with you nice people. : ) 4. See Jobst's mention of testing for arm alignment. Arms are aligned but this concept makes me think that working the arms might loosen the remaining fragment. I reinstall wheels and stand on arms, with some bounce, from either side. IT DOES! Fragment falls out. 5. Everything looks fine. New pin.
(The only reason I attempted this was to try to ship a very large framed bike at low rates. I would now try to avoid removing old cottered cranks no matter what! These were on a fresh, lightly used bike, clean---but still stuck!)
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Jeff Potter
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