1970 Norton commando 750 Cam chain idler gear shaft loose.

Has anybody ever tried enlarging an idler shaft to to fit snug in the engine case. The bore isint that bad. It looks like a thou or two. I can remove it by hand. Or has anyone tried making one oversized. I tried copper plating at home but it didnt change dementionaly after several coats. Or do they sell them in oversize. My brother has a lathe to make one but what about heat treating and scrolling. The shaft does have a slight wiggle side to side so didnt thing putting it back in with a locktight made for cylindrical parts would be safe.

With the minimal wear you describe, I think the shaft you have will work fine when supported by the timing cover.
If you have doubts, locktite the shaft in the case end only and before setup centralise with the timing cover.

Loctite and as its setting have the timing cover in place so it's in the correct position. Copper plating works but at home it does take a long time.

Sounds like someone has tried tensioninh the chain without the special holding bracket or scrap/modified timing cover in place to support the intermediate gear...which leads to wallowing of the bushing and also doesn't set tension correctly bc of the out of true gear.

Ok im going to try something my brain just thought of. I gave my brother the pin and he ground down the end of the pin to be .080 thou smaller and tomarrow we will make a sleeve and press it on the pin. then we will pinch fit it into bore on the engine case . wish us luck. ps I have the support plate.