What is the best tool to cut an axle?

[shenzhen_ex]

I need to cut (shorten) my axle on the side with the wires :?

Any suggestions before I make the cut would be appreciated.

Has anyone ever used this type of tool to cut an axle? I have access to this tool.

Other tools I have acess to that may be used to cut the axle:
-Hacksaw
-Manual milling machine
-Angle grinder
-Dremmel type tool w/ cutoff wheel
-Bed lathe

 

[izeman]

the tool you show i for cutting tubes. not for cutting solid axels.
i would go for the grinder. just screw on the nut first, so the threads will be kind of recut when the screw is removed. before removing the nut use a file to remove sharp edges.

 

[izeman]

btw: you didnt say if it's the axle only or if the stator is installed on it. with the stator and maybe phase wires installed, a lathe is a no go
if it's the naked axle then the lathe is preferred.
a dremel may work but will eat some discs during the cut.

 

[shenzhen_ex]

btw: you didnt say if it's the axle only or if the stator is installed on it. with the stator and maybe phase wires installed, a lathe is a no go
if it's the naked axle then the lathe is preferred.
a dremel may work but will eat some discs during the cut.

It is a complete gear motor. I might cut the wires to swap in waterproof phase and hall effect sensor connectors.

 

[shenzhen_ex]

the tool you show i for cutting tubes. not for cutting solid axels.
i would go for the grinder. just screw on the nut first, so the threads will be kind of recut when the screw is removed. before removing the nut use a file to remove sharp edges.

Thanks for the tip on using the nut and file.

I am not sure how i will be able to remove the sharp edges on the hole where the wires exit. I guess "very carefully" is the answer.

I wounder if the axle is mild or hard steel.

 

[knighty]

angle grinder, with a 1mm cutting disk in it (make sure it's not a grinding disk)

as above, screw the nut on, cut the axle, then screw the nut off... as you screw the nut off you should feel a bit of resistance... when it does this work it back and forth till it gets easier, then unscrew a bit more and repeat

 

[dogman dan]

It's mild steel, easily cut with a hacksaw. With those wires in the center, I'd be cutting very very carefully all the way around the axle, then try to grab the end with pliers and pop it off without cutting all the way through. Then again very carefully, dress the burrs with a file.

If you are going to cut the wires anyway, you can pull the wires into the hub a few more inches. Make your hacksaw cut, then pull the wires back out. Now the nicks on the wires are outside, where you are going to cut it anyway. If not cutting the wires, you would still have any nicked insulation out where you can fix it easy.

 

[shenzhen_ex]

....If you are going to cut the wires anyway, you can pull the wires into the hub a few more inches. Make your hacksaw cut, then pull the wires back out.....

Pulling the wires into the motor seems like a really good idea. I found a picture of my motor with the cover off [credit spinningmagnets ]. It seems that pulling the wire into the motor might be difficult. That steel 3-phillips screw flange is pressed on. Is there a trick to it?

 

[dogman dan]

Yeah, that does look harder to deal with than the direct drive motors I'm used to. I don't know much about gearmotors. In my climate, I melted the ones I had pretty quick.

 

[spinningmagnets]

You can cut around the axle, and go slightly deeper each time (with an angle grinder?). When you start to see a crack forming, stop. At that point, you might be able to crack the tip off without damaging the wires or even breaking their insuation.

I have a small scar on my chin from a an angle grinder with a thin abrasive wheel kicking back on me. Be gentle and proceed slowly. I would not ever do that without gloves and safety glasses.

 

[Chalo]

Is the importance of shortening your axle greater than the risk of screwing it up, or the hassle if you do? It seems to me that the extra bit of axle offers a small measure of protection for the wires bending out the side.

 

[shenzhen_ex]

Is the importance of shortening your axle greater than the risk of screwing it up, or the hassle if you do? It seems to me that the extra bit of axle offers a small measure of protection for the wires bending out the side.

I am shortening my axle to fit my forks.
I feel it is worth the risk!