Jake-
I looked into it before I bought my air hammer. There are several sites on line and some litterature around about rebuilding them. It seemed like too much work, too much of a learning curve, and too much time away from what I really wanted to do. The economics really didn't make sense for me. Do you already have a power hammer, and this is a second one for you?
Rob

I would like to let you know, but I can't get the clutch off the shaft. I need to get it off to get at the flywheel which is broken. (I am working on a 25 now.)
Actually, any reasonably good mechanic should be able to rebuild one of these as they are NOT hi-tech.They were originally put together with a wooden ruler, if I remember correctly. Not hi-tech as I say.

SmokyRick
Rick Crawford at Smoky Forge

I just want to reassure you that old power hammers that have a caste body are very straightforward .... the basic moving parts are logical and rarely need more than a bronze bearing replaced ( which any machine shop can make ).
The only headache is the rings ...I have muddled along for years with my Masseys and they have been moved around the world a lot when I do my in situ extravaganzas ...there have been times when they were working with cardboard and grease soaked ropes as gaskets .... I am not a perfectionist when it comes to machinery but they have been very loyal to me .....

From your writings I would guess that you are a fastidious person so you might not be able to sleep knowing that something is improvised so I have to warn you that Power hammers have this tendency to play tricks on you and demand your attention at awkward moments ...don't get too obsessed with making them perfect or they will take over your life ...

Think of them as a big guy with a sledge that needs talking to nicely and occasional feeding.

Jake, Typically with LG's you wind up needing to re-pour babbit bearings on the mainshaft, fixed a cracked sowblock, (after fighting to get the die key out), usually rework the guides and replace the spring and possibly repair or replace the arms. Little Giants were very near the bottom of the line as far as power hammers go when they were new. The smaller 25# and 50# LGs were aimed at the farmers and small rural blacksmith shops and weren't nearly the quality of a Fairbanks, a Beaudry or a Bradley, to name a few.

Since you seem to be a busy guy, with work coming in regularly, I'd think it would be a waste of your time to mess around trying to rebuild a hammer you don't really know intimately enough to fully and correctly diagnose before buying. You could get a real lemon that isn't even possible to rebuild.

For about $7k you could get a brand new 100# or bigger Iron Kiss air hammer, arguably the best one currently built. At least in my opinion. They're made in Baltimore, MD, so you'll have to pay some freight, but it would be worth it to get a hammer that runs perfectly right out of the box, so to speak, and has the power and control that other hammers only envy. http://www.ironkisshammers.com 

You would, of course, need a good air compressor to operate an air hammer, but you neeed a compressor in the shop anyway.

If you are determined to have a LIttle Giant, then by all means contact SId Suidmeir, the owner of the Little Giant name these days. He rebuilds them, stocks some parts, and is free with advice. He's also in Nebraska, which should be pretty handy for you. http://www.littlegianthammer.com/

Good luck, what ever you decide to do.