How do i cut an axle to my custom length without powertools

Please let me know if you have any ideas

hacksaw

9 Likes

Bolt cutters, hacksaw, the slightest bit of effort. I’m pretty sure you can cut a 1/4” shaft with an intense glare.

7 Likes

Have you always used power tools to cut 1/4” shafts?

don’t use bolt cutters, it makes for a very sloppy cut, which can cause issues when trying to put gears or stuff on the shaft.

6 Likes

We cut them like that and then file them down. We like to file them down anyways for less friction so the bolt cutters are convenient.

2 Likes

If you want an incredibly sloppy cut, you can a low strength shaft by bending it back and forth repeatedly. No tools, power or otherwise, required.

4 Likes

That’s also how you get a bent shaft lol.

If you were super desperate to have a cut perhaps you could simply file it in half with the sharp edge of a file and just grind through it.

when I don’t have access to power tools, I prefer the “rub two shafts together” method. Over time, the shafts will erode each other to the point of breaking. takes a little longer than traditional methods, but you end up cutting 2 shafts at once so you end up saving time.

5 Likes

Back to some “real answers” to the OP:

You need a hacksaw with a fine-tooth blade, a file, and preferably a vise. Our robotics teams rarely use power tools for cutting. Sometimes a Dremel tool is used, but usually only when the axle is installed on a robot and must be cut “in place”.

Besides your local hardware store, here’s a good source for a hacksaw, fine tooth blades, and a file: https://www.robosource.net/46-saws-files-drilling

If you don’t have many tools at all, you might consider their team tool kit, which has most everything except a file: https://www.robosource.net/tools/263-full-team-tool-kit-for-star-torx-drive-screws.html

Next, go to your nearest Harbor Freight and get a little vise, maybe this one: https://www.harborfreight.com/2-1-2-half-inch-table-swivel-vise-97160.html Be sure to use a 20% off coupon (you can get a HF coupon app on your phone)

9 Likes