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Re: pic: shaft
6061 isn't a great alloy for transmitting torque through keyways or such things with high stress concentration factors. 696 used 1/2" axles with 1/8" keyways out of 2024 Aluminum (McMaster pre-keyed stock) last year with 5" wheels geared for 9fps with two CIMs on each side and never had a problem with them over two regionals and championship. But 6061, I doubt it would have survived.
Another important thing is to make sure your key fits tightly with no backlash.
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