I have brass sleeve bearings for the axle, but either the axle is a little bigger than 5/16" or the bearings are a little smaller, because they don't fit. The right way to remedy the situation would be a lathe. I don't have a lathe. I chucked the axle into a power drill and sanded a few thousandths of an inch off it.
I'm going to have to do some work to carve a sort of Philips head into the end of the drill rod, in order to mate it to the DeWalt gearbox. I'm not looking forward to this, I'm a butcher with a Dremel.
Fortunately, I haven't yet welded anything in place (I wanted to have the axles built in order to help with the alignment of the posts). My new plan is to weld the inner post in place, and then make a kind of bracket for the outer post, to keep it from moving forward, backward, or inward. The layer of polycarbonate armor will (knock wood) keep it from moving outward.
I've done some tapping of the holes (note the bolt in the upper left of the picture). It's very relaxing work. I'm sure I'll continue to enjoy it until I break a tap.
By the way, the camera I'm using to take these pictures is the one that is included with Cosmopolitan Virtual Makeover 2. I bought it on sale a local software store because I thought that $20 for a digital camera was a pretty good deal. I may use the software later to show my robot with a new hairstyle.
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