Alignment tool completed - better, or not?

[@polarbearchimney]

Great work on the alignment! Just wondering-why didn’t you go for a 13mm hex-bar? I heard they naturally align themselves better due to their extra millimeter of torque leverage. Seems like it could’ve saved you some welding effort!

[@DClarke1954]

Hi, I went for 12mm because that is the pre-made hex-hole that exists in the cassette carriers ratchet assemblies. It seemed easier to have it common on both sides. Theirs is perfectly formed and part of their expensive production machining. I am just replicating this on the LH side with a rotary broach. Then they are common, and I can use a 12mm bar as an alignment tool. Made sense to me. 🙂

[@polarbearchimney]

@@DClarke1954 Thanks for explaining! That makes sense for standardization, but wouldn’t using a 13mm hex-bar offset the broaching angle slightly, creating a natural preload effect on the alignment? I read somewhere that this can improve torque harmonics, especially with rotary assemblies. Just wondering if that’s something you’ve accounted for.

[@mikemelbrooks]

I dont mean to teach you how to suck eggs but, If you add more 8mm nuts to the end it should run truer. PS some freehubs are made of alluminium, you could probably turn the bore down to make it a better fit on the shaft, and instead of welding it secure it with a grub screw!

[@DClarke1954]

Yes, it was just a simple alignment test. There is a 12mm AF brass bar in the middle aligning the 2 output sides of the 2 freewheels for welding. It gets removed after welding and then the 2 half-shafts are inserted on either side. Normally such units are >£200-400 but this has cost