Summer Project 2 - Star intake rollers

[marccenter]

Dear CD,

Here's some pictures of summer project 2 - star intake rollers.

Andy mark sells some intake roller stars but I wanted to take a stab at making my own for less. So, after some contemplating I grabbed a EVA foam, VEX floor tile, 0.88 inches thick and cut out a hex star from a water jet. This
the is same kind of EVA interlocking floor tile you can find at Lowe's or Home Depot. Comments follow:

1) Measure twice, cut once - how many times do I have to learn this lesson? A 1/2 hex shaft is too small for the cutout hex.

2) Using a banebot 2-7/8 wheel, hex inside wheel in the inside, I manually cut out an inside circle and fitted the star onto the wheel. What do you think?

Next steps,

1) Cut the right sized hole in the middle. Evaluate if the star will spin in the shaft. Potentially use weldwood cement glue to hold in place (metal to EVA foam). Evaluate durability on a spinning shaft with 2013 frisbee.

2) Water jet cut the inside circle to fit the Banebot wheel. Evaluate durability again with and without glue between the banebot wheel inner and the EVA foam outer.

What are your summer projects?