Originally Posted by
2jmotorsports
.... I am now having trouble getting the sprocket far enough away from the frame to allow the chain to be installed without hitting the frame. Considering all parts are the same as before with the exception of the slightly sanded cotters, would it be possible they are causing my clearance issues?
Don't blame the cotters. One possibility is that the axle isn't symmetric, and that you've put it in the wrong way. Another is that the cotter flats on the axle are wide enough for some adjustability and you didn't get them back in quite the same position.
Or maybe you've switched to another size/number of bearings?
What I have done in similar situations is:
1) dig deep in my parts bins. There can easily be some difference between axles and bb cups. Some combos will work where others won't.
2) Cut down the BB shell a little
What I haven't tried so far is widening the cotter flats on the axle, but apart from irrepairably altering a part I can't see anything mechanically "wrong" with it. A cotter that's gripping well enough to deal with pedalling push should be ample to deal with the sideways loads.