Summary

Originally found this idea on buildlog
http://www.buildlog.net/blog/2011/09/new-brushless-dc-router-spindle/

Since I could not find source files, I created these on openSCAD and added few variations based on material I am using (10mm PE or DelrinPOM).

Instructions

Got the 4 parts milled on the cnc, the top part needs to be done on 2 passes. Found simpler to mill from the side of the bearing inset, and then bottom pocket for the motor. I did that using the drills for registration pins. On my CNC these 4 took about an hour, 2mm layers. On a 3d printer this may take a long time.

I refined measurements on lock blocks too for tolerances. Heeks file is best for milling operations, I may add the gcode files but depends on your machine mm or in (mine is in mm) and my speed is 300-400mm.

Still work in progress. I will upload more pictures with the MXL pulleys assembled. Press fitting the bearings is a job, also I am not sure of the wave pressure washer to preload the bearings.

CNC Spindle using brushless RC motor