When writing my post I didn't realize that the grooves were E-clip grooves, which makes the smaller diameter of the shaft a greater issue, nor did I realize the failure occurred as a result of bending forces. My bad.
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Originally Posted by sst.thad
After looking at that one groove, it was actually machined too deeply. Normally we turn the shaft down to .44 for the groove, but that was was closer to 3/8th. Also you are right that was the eclip that held the bearing in on the wheel side of the WCD. The prototype we are building right now uses spacers with eclips on the end, which should make this less of a problem.
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One thing to consider - do you need an e-clip to retain the bearing? On our set up, we just have the wheel itself physically constrain the bearing - there's no space between the edge of our wheel hub and the inner bearing race. Sure, a bearing could possibly wiggle loose during a wheel change, but that's not a hard fix anyway.