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A2
@ JamesNewton
It would be difficult, but not impossible to manually reduce the diameter, and maintain a concentric relationship with the the thread body.
I would question how ridged it would be under load.
Actually, it isn't all that hard if you have a hand drill, a clamp, and a good file. You just chuck the rod, then lock the drill on, and file until the thread are just gone. The point where the threads disappear into the shaft is an easy and very "automatic" stopping point. I've done that before with standard threaded rod with great success.
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Solidus Labs
@ JamesNewton
Perhaps the simplest solution would be a printed coupler that is 1/2-10 thread on one side and 5mm on the other. Like what is used for the prusa z . [www.thingiverse.com]
Most of the load is axial so I wouldn’t expect too much flexing
Yes! That is a simple, effective, and very obvious solution. Thanks!