Stubbing a new shaft extension onto the original shaft can be frowned upon as sound reclamation practice! However in this example a successful guaranteed long term repair was carried out using this method. The ABB servo motor was sent to us by a new customer following failure of the shaft on a particularly arduous site application. We found that the shaft extension had been metal sprayed by others but the bonding had failed. Our Servo motor technicians dismantled the motor with the damaged rotor being given to our mechanical technicians for assessment. In this instance it was not practical to press out the old shaft from the rotor pack, therefore after careful consideration and in full consultation with our customer it was decided that a stub shaft would be manufactured and fitted. Our mechanical technicians created a CAD drawing for the stub shaft and assessed the material grade of the original. After being made, the stub shaft was secured to the original in a rather novel way. The completed rotor repair was dynamically balanced to G1.0 and new bearings were fitted. Upon reassembly of the motor, the resolver was aligned to the OEM specification. Besides the normal dynamic load testing, extended overloads, much greater than would be experienced on site, were inflicted upon the motor to challenge the integrity of the repair. This unconventionally repaired Servo Motor has proved very successful on the customer's plant having being put on a machine operating on a greatly increased load factor.