"Tim Wescott" wrote in message
...

snip

I'm thinking that one could machine ends out of aluminum, then plug them
into a thin-wall (.035"), 1/2" or 5/8" diameter tube made of 2024. I'm
also thinking that bonding everything with epoxy would be a valid way to
go -- but I'm not so sure about the epoxy in a part that's going to be
subject to lots of vibration in at least eight of the six available
degrees of freedom.

Threading such thin wall tubing makes me think that it'll just break.

Welding makes me think it'll never happen.

Soldering???

--

Tim Wescott
Wescott Design Services
http://www.wescottdesign.com

I used to have a Testors BD-5, can't remember if it had a shaft extension or
not.

Some of my R/C helicopters have a shaft drive to the tail rotor and use
arrow shaft. Some use aluminum, some carbon fiber arrow shafts. These
aluminum one have inserts, can't remember for sure if they are glued in or
shaft internal, collar external clamping to the shaft. I would consider a
carbon fiber arrow shaft with aluminum fittings epoxied on, perhaps JB weld
or other strong epoxy. You may want to look at some R/C heli parts, lists
and exploded views are available online.

RogerN