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For something that simple, you can sketch it with a Sharpie® on the back of a fag packet. I think I paid the machinist £40 for the axle + spacers, using my own material, and the bolts were about 50p from the local shop.
You can either leave the spacers loose or spec the ID to give an interference fit on the axle, according to preference. The hub gets squeezed between the spacers when you tighten the bolts, which is why the axle needs to be a smidge under 120mm.
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gbj_tester
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Excellent, thanks. Is that half a mm usually bang on for loading the cones, or do need to tweak the bolts a little to remove play in the bearings?
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I've decided to have my local machinist make up one of these axle inserts for an upcoming wheelbuild.
I was wondering:
Do you mind if I borrow the design?
Did you do it in stainless steel or in aluminium alloy (and if the latter, what grade did you opt for)?
Did you find the 119.5mm length allowed for adequate tolerance when tightening the screws? I'm assuming elastic extension of the axle under tension is negligible; I'll do the calc but can't recall a good rule of thumb to relate tightening torque to axial force just now (and haven't chosen my material, see above)
It looks like you've used off the shelf button screws with regular washers - is this the case? I was considering using countersunk machine screws with corresponding countersunk washers, but if -say- you found that serrated washers were needed to avoid slip, I would rethink.
Thanks in advance.
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Hey Tester
If I was going to make this myself, would 7075 bar be suitable for this application? It's high strength as I understand but I know very little metallurgy
allensea
Cupcakes
PhilDAS
What sort of price would I be looking at for a one off like that? Also, I was wondering what sort of file formats machinists work with, or is just a plan old drawing okay?