How to put a Harley Davidson wheel on a Honda VTX 1300
Super simple and safe
the only thing you need to make sure is that the ends are square and the length is correct - a bit over is fine as the bearings will work if they are a thou or two out the housing.
If the spacer ends up too short you will be pinching the bearings, forcing the balls to run on the sides of the grooves = short life.
The length of the internal spacer should be long enough that it's flush with the inside of the bearing races, but not so long so that it sticks. Basically, measure the distance between the bottom of the bearing seats, and make the spacer one or two tenths of a millimeter shorter. If it's too long, it can allow the bearings to wander in the seats, potentially causing adverse handling.
When the bearings and spacer are fitted to the wheel, the spacer must be trapped by the bearing inner races when everything is snugged up - if you make it shorter so the spacer does not abutt the bearings then the bearing will fail soon.
To suggest otherwise is wrong.
the spacer must never be shorter than the shoulder to shoulder distance, but longer is OK.
tube, pretty much any aluminium alloy will be fine, or steel if you don't care on the weight. As for phosphur bronze... WHY? Adequately strong, but it's a bearing material and heavy. I see no bearing.
The tube ID needs to be slightly larger than the axle diameter to allow the axle to pass unhindered. Drill (and ream or bore) as appropriate, at least 0.1mm oversize. The OD can be calculated if you want to be pedantic, but for such low stress, just make the wall at least 5mm thick for aluminium alloys or 2mm for steel and you'll be just fine. The length is the critical point, as a lot of the other contributors have pointed out. Measure and replicate the original spacer, or fit one bearing to the wheel and measure the depth from the other bearing seat to the inner race of the bearing. You need to be slightly larger than this. 0.05mm oversize will be just perfect. Simples.
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