Hi there! Our team is currently using vex parts extensively. Its only our 2nd year using the system so are still struggling for how to machine the aluminum parts for maintainability and reliability. Last year we had an intake roller system that used a 1/2in hex shaft with clamping bearing blocks. But we didn’t provide an easy way to remove the shaft to service it. When the shaft has many parts on it, flex wheels, clamping shaft collars, etc, it takes too much time to remove the shaft to service it. We had many occasions of using a rubber mallet to pound the shaft onto and off of the aluminum tube.
This year we are considering “notching” the versaframe in order to slide the entire versablock & shaft assembly to be taken off of the end of a 1in x 2in tube. Illustrated in the below picture, using 3/4in width to provide the 1/2in hex plenty of distance away from the tube to prevent grinding.
Does anyone recommend or not recommend doing this? If you recommend, which power tools would you recommend? We have a drill press and band saw. We tried using a 3/4in hole saw to create the initial hole and then a reciprocating saw to cut from the edge to the hole. But the cuts came out very rough and jagged. It was hard to see line while using the saw. In addition, we have this style of metal cutting style saw which makes this cut difficult because its designed for cuts perpendicular to the tube.