ServoMods

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Servo Modifications

Also checkout GearBoxes

This is a servo modification where I add an extra external gear to the gear reduction train that reduces it by 6 and gives you sprocket drive or 1/4 inch steel shaft options. I also make a single or double winch drum option in place of the sprocket.

The mold is made of PVC and nylon.

The little round inserts are dummy bearings that are the same dimentions of the bearings to be used.

In this picture you can see the Kevlar showing. Placing a continuose loop of Kevlar or fiberglass in the mold was suppose to make it stronger but it caused bubbles in the epoxy/graphite composite to get trapped. For all of the rest of them I chopped the Kevlar into bits no larger than 1/2 inch and mixed it in with the composite. If you don't have any areas of the part you are making thinner than 1/4 inch and longer than 2 inches you could get by without the Kevlar. The Graphite mixed at about 1 part epoxy to 2 or 3 parts graphite makes a strong machineable matireal that can be drilled and thread tapped. I was able to tap #6-32 threads that don't strip out after many dissassemblies.

• a special warning however, adding graphite to the epoxy of a thin fiberglass of Kevlar layer like a boat patch or car body work will make it much more brittle. Its OK to mix in for the top coats as it will help smooth out, hide the fiber texture from showing thru and it sands well, just don't use it for the fabric layups.

For this one I cut off the original servohorn spline and made a 1/8th inch steel shaft with a flange base that I slotted and textured so I could epoxy it into the gear in the space normaly occupied by the feedback pot. The feedback pot can be relocated to the final joint shaft being driven or dissregarded and instead of a servo you can bypass the circuitry and hook up power directly to the motor if no feedback is needed. The output gear originaly has a tab to stop it from full rotation but I shave that off.

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