Metal Axle Conversion 1:64: Chassis, Drill Jig and Wheels for Real Metal Axles

An optional metal axle setup for the 1:64 swappable-body toy car chassis. Instead of paperclip wire, each axle is a hollow metal shaft with a small mushroom-head nail glued into each end. It fits the free R1 Roadster 1:64 and all four Garage Starter Trio 1:64 bodies (Hatch Coupe, Pop-Up Coupe, Pocket Roadster and Pocket Roadster Hardtop) with no changes to the bodies: they push onto the same posts as before. Cars and axles are not included.

• Print-in chassis: the axle holes print in place as small teardrop holes, so most printers need no drilling.
• Drill chassis: solid axle blocks with small pilot dimples. Drill them to 1.0 mm for a cleaner round bearing.
• A two-piece drill jig (cradle and guide plate) that holds the chassis square and guides the bit through the axle blocks.
• Classic 5-spoke wheels for metal axles, 11 mm front and 12 mm rear, in easy-print (0.4 mm nozzle) and showcase (0.2 mm nozzle) versions.
• Two-colour option: classic 5-spoke rim cores plus the standard tyre rings, the same rings the Wheel Pack uses. They press onto the metal-axle cores with a light 0.05 mm per side fit (checked in CAD).
• STEP files for every part, and editable SolidCraft source for every part except the tyre rings, which come as STEP, STL and 3MF only. The PARAMETERS guide is included. Change the shaft or nail size once and every hole, bore and counterbore follows.
• 14 parts in all, each as STL and 3MF, plus a guide (PDF and Markdown) that covers measuring your axles, printing, drilling with the jig and assembly, and a spec sheet.

Metal-axle versions of all nine Wheel Pack 1:64 styles come with the Wheel Pack.

Axles: use a 1:64 replacement axle kit with 0.98 in (24.9 mm) shafts. That length fits 11 mm and 12 mm wheels. The 1.10 in (27.9 mm) shaft only fits an axle with 12 mm wheels on both ends. The shaft diameter (0.8 mm), nail shank (0.5 mm), nail length (10 mm) and nail head (1.0 mm) are assumptions until a real set is measured. Measure yours before you print; the PARAMETERS guide shows what to change in the SolidCraft files.

Drill bit: 1.0 mm, or a #61 (0.991 mm) or #60 (1.016 mm) number bit, in the jig. Ream the wheel hubs to 0.75 mm (#69) and press them on, or glue them.

Paperclip parts and metal-axle parts don't mix: the metal shaft is thinner, so paperclip wheels and the standard chassis won't grip or guide it. Use the parts in this kit.

Printing: PLA, 0.4 mm nozzle, 0.12 mm layers, no supports. FDM only; there are no resin files for these parts yet. Each chassis is about 3.2 g and 45 min; the jig cradle 23.3 g and 2 h 50 min, the guide plate 4.6 g and 47 min; easy-print wheels 0.6 to 0.8 g and 11 to 14 min each (slicer estimates). Print the small wheels as a set of four or add a 2 mm brim.

You'll need a 1:64 replacement axle kit with 0.98 in shafts (two shafts and four nails per car), thin CA glue, a pin vise with a 0.75 mm (#69) bit, and for the drill chassis a 1.0 mm bit. An adult does the drilling and gluing.

CAD-checked, not print-tested. Fit was checked in CAD on all five bodies with every wheel turned through a full rotation (at least 1.0 mm clear of the body), and the shafts and nails clear the bodies by about 3 mm. The axle sizes are assumptions and the grams and times are slicer estimates, so let me know how yours prints.

For ages 8 and up once built. Small parts: not for children under 3. Drilling and gluing are adult jobs.

Licensed by Raymond Thurman, doing business as SaiyanPrints.