Aluminum Idler Wheel

thingiverse

To fix our faulty idler wheel, we created an aluminum replacement that performs exceptionally well. Following Makerbot's guidelines, we crafted a wheel with an outer diameter of 1.614 inches and an inner diameter of 0.862 inches, both from 1/8-inch thick aluminum. To ensure a strong bond between the wheel and bearing without using glue, we milled an inner hole slightly smaller than the acrylic hole (0.806 inches in diameter). Next, we heated the wheel over a gas flame to expand the hole for a snug fit of the bearing. By placing it on Makerbot washers and ensuring the right height, we then inserted the bearing into the hole. To prevent excessive heating of the lubricant, we rapidly cooled the wheel with water as it returned to room temperature. The end result is a secure, permanent bond between our aluminum wheel and the bearing.