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Re: ThunderHex inspired question
If you're already thinking of turning a hex shaft down to fit into a round bearing, I'd recommend using a small enough bearing that you get 100% contact. The sheet metal on bearings is mostly meant to hold the bearing together when it is between assemblies, not to distribute the forces tangentially.
A less desirable alternative would be to add a spacer with a hex bore and an outer diameter that fits into a larger bearing. This would also need to be held in place with a shaft collar or similar.
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