Cotter Pin Misadventure

 I was fixing up a Peugeot UO-8 with super stuck cotter pins. My usual method of using a C clamp and a socket as a spacer didn't work this time. I added penetrating oil and let it sit for a few hours, then used a propane torch on the crank:

 

 

This still didn't work, unfortunately. Even after tightening the clamp and hitting it with a hammer, the pin refused to move. I left the nut loose, sitting slightly past the end of the pin. The pushing force from the clamp ended up stripping the threads off the threaded end of the cotter pin:

 With my first attempt unsuccessful, I left the stripped retaining nut loose and then rode the bike for about 12 miles. The next day I applied more penetrating oil and let it sit for another 8 hours. Then I rigged the crank up with a large portable vise, and cranked down on the handle:

This time, the cotter pin moved:

Next I could pull the pin out and slide the left crank off the spindle. Here's the old pin with the threads that I ruined earlier:

Onto the drivetrain side. The existing cotter pin on this side had already been smashed and bent over by someone else's unsuccessful attempt with a hammer. I decided to unbolt the chainrings, and unscrew the right side bottom bracket cup from the frame so that I could put this assembly on a work bench.

Taking a tip from the great Sheldon Brown, I used a pedal spindle to drive out the remnants of this cotter pin. It took a few hard hits, but it came right out after heating the crank with a propane torch:

At this point I thought I was done, but this crank still didn't want to slide off the spindle. I had to clamp the spindle in my small vise and heat it again with the torch in order to rotate the crank off the spindle:

I'm impressed by how much this crank was able to fight me. It was like trying to take an old rusty car's suspension apart. At least now I can service the bottom bracket bearings and clean out the 50 year old grease. Cheers.