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Re: Cantilevered Wheel Shaft Strength
Keep the length of the cantilever as short as possible. Avoid notches, holes, diameter changes, or other stress concentrations in the cantilevered portion of the shaft. .5" round or hex steel (4140) is pretty darn safe. If you're going to use aluminum you should do some math (Google for cantilevered beam equations and allowable stresses for your shaft material). Hint: wcproducts.net has some nice 7075-T6 .5" hex shaft stock available.
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-Joel
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