Materials

Motor Assembly

Motor shaft 

TODO: link to drawing

The shaft connects stepper and wing. It is made from a 1m anodized aluminum shaft.

There was an attempt to make the shaft with hardened steel. The metal was very hard to cut and drill with the available tools.

Method

1. Shaft was cut to size with the Femi metal saw. 
2. Center hole was drilled with a mini lathe. 
   The hole was first drilled with a center drill. Then it was drilled with a 4 and 7,5mm twist drill bit.
   Make sure the shaft is not wobbling before drilling. The shaft needed a lot of adjustment before it was stable.
   It is also important to use lubricant oil when drilling. 
3. Chamfer on the sides of the shaft was also made on the mini lathe.
   A Form tool was carefully used at an angle. Moving the tool too fast resulted in the shaft rotating off axis.
4. Holes on side was drilled with a drill bench.
   A straight line was first drawn to use as a reference. Hole on top and bottom must be aligned.
   Hole for the wing was marked by placing the wing on the shaft, aligned with the line.
   The first hole for the magnet holder, was measured from the edge.
   The second hole was marked by aligning the magnet holder on the first mark. 
   All holes was first pre-drilled with a smaller twist drill.
   Using a center punch is recommended to make sure drill bit is not drifting.
   Drilling speed was selected from the table at the wall. (fast with small bits, slow with thick bits)
5. The two holes for the stepper and magnet holder was tapped to fit a machine screw.
6. All hole edges was smoothed by hand with a larger drill.