I've seen all kinds of creative solutions to personal needs on this forum. Here is one of mine.
Being 6'2" in a 2006 Sport, I always desired having a longer pedal throw without hitting the hull, as seems common judging by other posts. So I decided to try making new cranks with added length of 2 1/2 inches.
I bought solid aluminum squarestock from one of the several online sources, less than $15 for 36" (I measured the original hollow cranks, forgot whether they are 3/4" or 11/16"). There were 4 holes to bore: One for the fulcrum, one for the adjustment pin, one for a machine screw at the top to secure the pedal shaft, and one for the pedal shaft. This one was stepped to match the shaft profile.
So with a drill press and vise, the right size bits and bores, and a tap I was able to actually improve on the original crank! A smashing success.
The increase in throw length is noticable but not as great as I had hoped. However I also gained more pedaling leverage, and now I can alternate 2 pin settings instead of just one as needed.
You may also notice I have replaced the plastic pedals with custom ones also made in my shop, out of Trex cutoffs. I like them because they are reversible, and with wet feet in warm weather, they are very comfortable.
