[Orion.DeYoe]

My team machines our own conveyor rollers. In prototyping we used 2 inch OD PVC pipe and machined hubs that press into either end. We drilled two holes through the PVC drum (at either end) and spiral wrapped urethane cord (AKA polycord) around the roller using the holes as positions for anchoring the ends. It worked beautifully. On the final bot the rollers will be made with .065 wall aluminum tubing instead of PVC.