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Originally Posted by Chief Hedgehog
I concur on the Thunderhex. What a horrible product - we had one student that spent about 2 days just filing down the Thunderhex so that we could use it. We will be looking at other stuff for next year.
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It's worth noting that ThunderHex is actually supposed to fit really tight, as theoretically it eliminates the need for collars and can fricton-fit through holes meant for round shaft. We use a ton of it on our robot and we never needed to sand it down to fit.
However, looking at the webpage I do see their notice that their current inventory is oversized due to a manufacturer error, and I do see how working with that could be a bit of a nightmare