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I have a wizard whose staff keeps on breaking (at the same point). Have thought about trying to pin it (too small), or replace the rod but then was thinking if you could fashion a sleeve for the two bits of metal, then glue it in place.

I was wondering if anyone had tried something like this before? I was thinking about seeing whether I could do something like this using a thin piece of aluminium wrapped around the point where it keeps breaking and then glued into place. The edges of the sleeve could then be tapered back into the rest of the staff using greenstuff. Thoughts?

Can you show up pics of it?

Your best bet for something like this might actually be to use something called "Heat Shrink" (may be called something else in your part of the world)

It's used a lot in electronics to secure wires and connectors. YouTube it, it works great on metal models in conjunction with super glue. (I always recommend Locktite Profesional Liquid. Best Super Glue ever!)

How thin is the shaft?

I've pinned shafts as narrow as 0.75mm before (it's not easy, but it's not "too small to pin").

In the case of the shaft itself being too small to pin, replacement of the shaft is often an option instead (have also done this. Remove original shaft, drill hole through hand, remove head of staff. Replace with brass rod cut to size, drilling out the head if needed to fit it back on.

Sleeve isn't a bad idea if it doesn't make it too much thicker and you can hide it well enough, it should be stronger than pinning if you can make it work. You could use thin brass shimming material and wrap it around.

But no I've never tried it.