Ok, here are some pics of the notch and crank that I had a request for more info on. Thought I'd post them here if anyone else was interested.
The notch is a little under an inch wide. It does still have sharp edges, which I intend to grind or file a little rounder and then paint. This should make them not as risky for catching your hand on accidentally.
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Here, most of my tape fix has been removed, and you can see the crank finger hits right at the edge of the notch when folded down. I think I notched it too deep, so the finger needs to be longer to stay in the wheel's notch. I think I'm going to put some heavy tubing around the finger to make a sleeve that goes past the end of the finger and will stay in the notch.
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You can see the notch is just slightly wider than the crank finger. This is also the width of the bench grinder wheel I used to make it.
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