Dust cover
OK Dude,
So you got the coaster brake arm off, and now (if you are like me on both of my builds) you are thinking, "well great, the sprocket doesn't fit over the dust cover!" Now what? Well you can have someone machine out the big hole in the sprocket so it fits over. You can pitch the dust cover. Or you can "fix it."
Try this.
1. Take that dust cover to your bench grinder or dremel tool.
2. With a grinder, shave off the bottom lip until the dust cap is smooth around the bottom edge. (see pic - in photo it is already smoothed out. Sorry, no before pic).
3. When your have smoothed it all out clean it up and re-install on Top of the sprocket. Then put the washer, coaster arm, and nut back on.
4. Check the wheel to see if you have shaved enough off. The wheel should roll freely without the dustcap rubbing excessively on the sprocket.
5. If its ok, your ready to roll. If not, then shave a little more. If there is just a slight rub, this is ok. Take your bike for a pedal spin around the block and it should be all gone.
6. Last re-install everything and get on with the rest of the build.
7. Will try to attach photos (We'll see!)
Good Luck.
Charlie