GearBoxes

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Making my own gearboxes is much the same as ServoMods but instead of extending a servo's gear train I make the whole thing from scratch. The ones I made for the TaiChiArms had a set of slotted holes for the motor mount so they could be interchangable as well as the pinion gear. The output gear and shaft can be assembled with a sprocket, single and double winch drums,pinion gear or shaft drive making for a very versitile transmission.

First I get an idea for how I want to layout the gear train combo.

Next I made a mold for the interior space of the box with holes for the shafts. This assembly forms the motor mount. The smaller piece with raised areas in the photo to the left is the mold insert that forms the slotted holes for the motor mounting screws.

This shows the mold outer surfaces being assembled with the over sized dummy bearings visible between the walls.

The fully assmbled mold ready to be injected.

After removing the mold insert the slots make it easy to adjust the motor to engage whatever size pinon/spur gear combo you want.

It also make it more versitile to mount differant motors with differant hole spacings. The white nylon disks on the shafts are the dummy bearings. Made the same size as the actual bearings will form the seats for the bearings when molded into place. A special set worm gear combo is glued together to make an alignment jig. Once assembled with the shafts in the molded case, final bearing seats are molded in. That is because I was having problems getting the holes in the molds to come out exactly lined up every time. This way I just use the shaft alignment jig to mold the dummy bearings into place after the case has finaly cured and settled into its final shape.

This one is assembled with a double drum winch. The gearbox assembled with the high torque racing motor mounted and the less current hungry Pittman motor sitting next to it.

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