Abstract: For use in a xerographic reproducing apparatus, a fuser roll structure comprising a core member having a sleeve carried thereby and a heat source disposed internally or externally of the core member. The fuser roll structure is characterized by the fabrication process wherein the sleeve is elevated in temperature above the operational temperature of the fuser roll structure and/or the core is chilled below ambient or room temperature. The sleeve is then installed on the core, and the assembly allowed to return to normal room temperature thereby creating a secure shrink fit of the sleeve onto the core. Structurally, the fuser roll comprises a sleeve the inside diameter of which is slightly larger than the outside diameter of the core when the sleeve temperature is elevated above said operational temperature and/or the core is chilled below said room or ambient temperature. At the operating temperature or below the aforementioned shrink fit exists.