In a message dated 2/18/2002 8:48:51 PM Eastern Standard Time, Bill_Bryant@prodigy.net writes:
> Can an axle be cut or ground down to the proper length
> > without weakening it?
> I didn't do this too often, but wouldn't worry about it. Where you are
> cutting is out at the end, while the place axles break is immediately
> inboard of where the cone assembly sits under freewheel threads. I can't
> recall seeing them break anywhere else.
> For this operation, I'd use a hacksaw, followed by a quick trip to the
> belt sander (or lathe) to dress the cut end before I tried ~grinding~
> off 5mm of threads--yow.
A hand held angle grinder with a thin (1/16") abrasive cutting wheel (AKA slitter wheel) works wonders. Remember to put the cone or a nut on first.