Here is how I make my own replacement shafts.
Finding the correct size of stock materials is the most difficult part of the process. I have had success using music wire, nails and suitable stock from eBay. I have found these 3.17 mm shafts
. I just received some today they’re look like they will work fine. All you will need to do is grind or file a flat spot for the motor bell to engage.
I also used this stainless steel stock
, it comes in 3, 4, 5, 6 & 8 mm. With this material, you will need to grind a slot for the clip. I chuck it in a drill and use a Dremel with the cheap cut off wheel to cut a slot. Don’t use the heavy duty wheel, it’s too thick. Be sure to wear safety glasses. Secure the drill, spin it up and with a steady hand cut the slot. On my first few attempts I cut the grove too deep. Just cut it off and try again. The Dremel also work great to grind the flat. The setup takes longer than the process, I will make several at one time.
For me this is a quick and easy way to breath new life into a motor. Like anything else it will be awkward at first but will become easier the more you do it You might want to order some extra E-Clips