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Re: how thin is too thin?
Yes, Sanddrag, you can certainly clamp a gear on the CIM shaft safely. We, and many other teams have done it. I think clamping is one of the most under used ways (in FIRST) to attach stuff to shafts. I wish I had some numbers, but from my experience, except when it comes to moving arms or other extremely high torque stuff (and maybe even then with a sufficiently large diameter shaft/collar), everything can be clamped on a FIRST robot.
I have also heard it recommended to use extra-strong loctite when clamping to improve the amount of torque you can transfer. Personally, I just make sure the metal surfaces are clean, maybe wipe it with rubbing alcohol.
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Team 1257
2005 NYC Regional - 2nd seed, Xerox Creativity Award, Autodesk Visualization Award
2005 Chesapeake Regional - Engineering Inspiration Award
2004 Chesapeake Regional - Rookie Inspiration award
2004 NJ Regional - Team Spirit Award
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