looking for advice on modifying front sprocket

There are no front sprockets available, anywhere in the world, for my recently accuired TC185. I have found a few sellers that claim they have one, but they turn out to be for a TS185.
So, I will attempt to modify a sprocket with a smaller shaft hole to fit a larger shaft. I have many common hand tools, a drill press, Dremel tool.
I'm looking for suggestions on how to enlarge the shaft hole and cut in the 18 cog notches.   

Those sprockets are hardened.  There is no reasonable way to enlarge the hole.

Maybe take some measurements and call JT Sprockets?  It may be reasonable to drill holes to mod the retain bracket holes if something otherwise can be found.

Nessism wrote:

Those sprockets are hardened.  There is no reasonable way to enlarge the hole.

Also the hole needs to be perfectly central

If you have access to a mate with a lathe and the old TC sprocket you could machine the teeth off the worn TC sprocket ( indexable carbide inserts will easily cut those sprockets) and then bore out the new sprocket to accept the remains which could then be pressed in and welded .
 

zed1015 wrote:

If you have access to a mate with a lathe and the old TC sprocket you could machine the teeth off the worn TC sprocket ( indexable carbide inserts will easily cut those sprockets) and then bore out the new sprocket to accept the remains which could then be pressed in and welded .

 

I think that may be the best option, it appears the TC has a unique dual range transmission and I can't see anything else with an 18tooth spline (the TS185 shares it output shaft with 39 other models) I used a similar method to create an off-set sprocket for my Harris 20 years ago (off-set sprockets for a CB900 just weren't available)

Its been nearly 15 years but I don't think it cost more than 50 bucks when I had a custom sprocket made