Quote:
Originally Posted by roboticWanderor
but then how were the ABS roller's bores made then? it seems a long bore like that would be almost impossible in a flexible material like ABS 
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There's plenty of ways of doing it. In 06 the NASA model shop made our competition rollers. They turned them to the correct diameter/length/put the grooves in.
They did the boring in two different operations. They stood them up on end in a very large CNC mill and used a series of drills of increasing length to bore all the way through. After they had the through hole they put them in another CNC mill and contoured the larger counterbore for bearings/plugs on each end.
That's just one way of doing them. They can easily be done on the lathe with enough travel, or very accurately by someone who specializes in gundrilling. Our rollers this year were made for us by another sponsor who did everything on the lathe but the hexes on the ends, which they milled.