Fabricating Soft Axles

[OneMoreRobot]

Not sure if this has been previously mentioned, if so, apologies.

Due to price & availability of some Soft Axles, in this case 19L Black asking price currently around US$50ea., I considered fabricating my own from cheeper donor axles of same colour, since Axle material appears to be TPU (Thermoplastic Polyurethane).

These are the simple tools required;

Tools by OneMoreRobot_NZ, on Flickr

Measure the length of the Axle to be fabricated, in this instance 19L approx. 151mmL;

Measure original by OneMoreRobot_NZ, on Flickr

Measure donor Axles, in this instance 11L;

Measure by OneMoreRobot_NZ, on Flickr

Cut donor axles, ensure ends are cut square;

Cutting tool by OneMoreRobot_NZ, on Flickr

Measure & cut donor axles to required length plus approx. 1mm ea. for wastage;

Cut by OneMoreRobot_NZ, on Flickr

Prepare pieces by OneMoreRobot_NZ, on Flickr

Clamp both cut axles firmly ensuring they are square & the axis are the same;

Clamp by OneMoreRobot_NZ, on Flickr

Use a heater or soldering iron with a flat blade, use the blade as a mirror to reflect heat into TPU Axle ends. Caution: Do not allow the TPU ends to touch the mirror. Caution do not inhale fumes if ends do touch mirror. Watch the axle ends swell as they heat - look for the 1mm each end to shrink. Remove heater & bring ends squarely together, do not push hard together as this will push out the molten TPU away & bring cold ends together. Be gentle, do not force molten TPU away:

Heater by OneMoreRobot_NZ, on Flickr

Heat axles by OneMoreRobot_NZ, on Flickr

Soft Axles by OneMoreRobot_NZ, on Flickr

Allow to cool naturally for a minute & remove from clamp. Trim excess TPU with a sharp knife or side cutters;

Trim by OneMoreRobot_NZ, on Flickr

Finished Soft Axles fabricated in a few minutes for a fraction of the cost;

Fabricated by OneMoreRobot_NZ, on Flickr

Installed;

Finished by OneMoreRobot_NZ, on Flickr

Anyone familiar of joining Polycord round belting will see this procedure is the same.

Hope this helps.

[DrJB]

Good initiative ... I guess what's on everyone's mind is:

1. The process seems rather involved (many steps and special tools)

2. Can you post close-up pictures of the connection points so we all get a feel as to how 'clean' the end-result is.

[Meatman]

I've tried making 19 long black ones with 2 common 11 longs before. I just measured them, cut them and glued them with loctite gel glue. It worked pretty well.