Joined: Nov 2006
Posts: 19,810
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From: NJ, NYC, LI
Bikes: 1940s Fothergill, 1959 Allegro Special, 1963? Claud Butler Olympic Sprint, Lambert 'Clubman', 1974 Fuji "the Ace", 1976 Holdsworth 650b conversion rando bike, 1983 Trek 720 tourer, 1984 Counterpoint Opus II, 1993 Basso Gap, 2010 Downtube 8h, and...
[MENTION=417491]Bikerider007[/MENTION], how does the length of the shorter cotter pin compare with the length of the hole in the crank, through which it's supposed to fit? The cotter has to be a little longer, like maybe 6 mm (1 mm for a washer, 5 mm for a nut), and a couple mm longer than that would be okay too (so a little bit sticks out at the other end). Is your cotter --the one on the right, the "too short" one-- shorter than that?
If the problem is that it doesn't fit into the crank far enough for the threads to come out the other end, you need to file the taper. Of course you should file the taper only when necessary*
*But as Fausto Coppi said, it was always necessary.
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