Thanks again,

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You will probably have trouble removing the entire sprocket casting, because of the sealer that was orginally used. Don't pry it out or beat it out with a hammer. That'll just deface the shaft, probably damage the bushings, or warp or break the casting.

Remove the sprocket shaft. All you should have to do is remove the taper pin from the collar. But be careful....I made the mistake of accidently slightly bending the sprocket shaft just by using a hammer and a drift pin punch. There are tools available made for removing those pins. A slightly modified motorcycle chain repair tool probably will work without damaging the collar, pin, or shaft.

The rest is easy. After you get the shaft removed from the casting, get a long bolt of the same diameter as the sprocket shaft and a bunch of washers, a nut, and a chunk of angle iron that will lay across the projector frame. Drill a hole in the angle iron to accommodate the long bolt. You should remove the door from the projector frame so you don't squish the hinges. (I recommend angle iron instead of flat bar because the flat bar will probably bend when you use it)

Put at least one washer on the bolt (that will protect the bearing surface on the casting) and insert the bolt in the sprocket shaft hole, all the way through and into the angle iron. Shim up the top with a bunch of washers if needed, and tighten down the nut snugly.

Then use the hair dryer or a heat shrink gun, and warm up the casting. After that, tighten the nut about 1/8 of a turn, wait a couple of minutes, then repeat until the casting is free of the projector frame.

By the way, you didn't say where the oil was leaking. If it was coming out the space between the sprocket shaft and casting, you should be able to clear the drainback holes in the casting by using a good cleaner and a toothpick or paper clip after the sprocket shaft is removed.

If it is leaking between the casting and the main frame, a good cleaning of the surfaces of the frame and casting will do, and re-schlop it with whatever you plan to use. Be sure to schlop the threads on the bolts, too!

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