In answer to questions recently raised on whether it is safe to resume using the cranks after the crack is filed out. I have done so numerous times without incident. In fact, it is probably safe to use them before the crack is filed out. Actual failure is fairly rare (there sure are a lot of bikes being ridden with them) , I believe, but it is nice to be on the safe side. Now another writer told how he filed the crack out to form a little flat spot. In leaving this flat spot, one creates two new minor stress risers. One should gently round out the corners left from filing.this only takes a few seconds.I like to use small rat tail round files and to remove no more metal than seems called for. A really neat job would probably finish up with a very fine wet sand on the filed spots, but I have never bothered and other riders I know don't seem to bother with that also.
Although this cracking has been brought up numerous times on this list, it is surprising how many unsuspecting riders you can show them to who are not list members and every one of them so far has been amazed to see them.
Lansing, MI USA