I’m looking for someone with a complete Robot II who is willing to measure the spools in the source and take-up cassettes for me. I just got a Robot II in very good condition. It has both cassettes, but they are missing the spools. If I can get good measurements, I am thinking of 3D printing the spools.
The Robot spools I have are diecast zinc or aluminum of the thinnest wall-thickness imaginable.
Comparing one to a modern plastic Kodak spool, it appears one could grind the ends flush and bush them with some comparable material.
You'll notice each half of the cassette has a small lip inside to keep the spool somewhat centered. Opposed to a modern plastic spool, the slotted end of the Robot spool is less that a quarter inch in diameter. This slotted diameter stands a mere 1/16" proud of the spool-proper. Like a modern spool it's less than flush with the top of the assembled cassette.