Quote Originally Posted by SamO View Post
Hi All
Been designing the gearboxes for my second feather weight for some time now, and it has to be said, I have made some pretty catostrophic errors in the design stage (i.e. brushless drive).
If you don't know everything of the motor, , nor have tested it, it's already difficult to make a gearbox for it.

I have since started my 4th or 5th attempt at this design, and really struggling with some of the basics.
I got the basics 25 years ago, in school.
For example: How do I attach gears to shafts?
Any means is good. from welding to grubscrews, from key and keyway to spline. Even glue will do, if used well.
How do I hold a bearing?
Simple methode. Buy bearing with their own bolt on housing. Like this one.
Less simple methode is very very accurate holes in plates (we're talking of 0.001mm jobs), or glue (for the small mistakes)
How do I attach the shaft to the bearing?
The shaft should fit snuggly in the bearing. If that ain't the case, there are bearings with longer inner races with grub screws. Otherwise it's glue-time again.

btw, for robot applications I prefer bushings. Way bigger tollerances, making it easier to work with.

Another thing that I am having problems with is... will it actualy work! (i.e. will it be strong enough etc)
That can't be predicted. But 1 thing is a fact. Keep It Simple.