Clutch release arm crack

In the last couple years, I have had to replace a few of these arms on my Model A's and on other owners' cars for the same reason. The clutch arm on a car of mine that I am restoring for its new owner appeared fine. But knowing the increasing failure rate these days, I removed it and put on the new stronger arm Y-Blockhead has pictured. It'd be just my luck that two months after the man took delivery of the car, that arm would fail. No worries now, besides imparting a little easier clutch action.
Marshall
 
I agree with Y-Blockhead, Post #20. The welded up lever looks substantial. This is too high a stress area for cast iron.

The original design had a key and a smaller pin. I think eliminating the key, and keyway, was a cost cutting move. Or did the original lever crack along the keyway?
 
A few years back one of the guys in my local A chapter tried a repro, and it would not work right. He came over one Saturday, and he and I drove the pin out and pulled one off the shaft. He tried, and tried to pay me, but I refused. He drives his car, and drives it on tour with us. I knew if I gave him the part it would not live for years and years on the workbench. I was happy to give it to him, and glad he got his car fixed.
 
I welded one back in the early 80's.I opened the crack up a little more with a grinder,clamped it tight with a pair of vise grips,and welded it.I planned to replace it,but kind of forgot about it.My friend has the car now,I'll have to remember to tell him about it.That one will have to be cut off with a wheel,I welded across the whole break,right over the pin.
 
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