Right Angle Gearbox Process Plans Page 1 of 5

Right Angle Gearbox Process Plans

Notes: 1. If you intend to drive the gearboxes with the motors, or in fact, drive anything with
more than 1 bearing with the motors, you will need to include a coupling in your design to
allow for angular and linear misalignments of the shafts. See Shaft Coupling Process
Plans for further info.
2. The tabs on the housing are intended to aid you in mounting your gearbox to the
same planar surface as your motor. If you do not need a set of tabs, and they get in the
way, feel free to chop them off.
Gearbox Housing
Using the housing.ord file off the RAG webpage, waterjet the housing shape from a
5/8 (0.625) piece of aluminum.
Find the drilling location guide notches, and mark a line halfway between the uncut
faces of the aluminum (0.313 from either face.)
Right Angle Gearbox Process Plans Page 2 of 5
Using a 3/16 drill bit (to pilot the hole) and then a V size drill bit, drill both shaft
holes with a drill press, or a mill for greater accuracy. Be careful when clamping the
piece to ensure that it remains straight and level while drilling. Misalignment of the
holes, and thus the shafts, could cause an inefficient or non-functional gear
alignment.
Bushings
Obtain a length of nylon hollow rod. Using a bandsaw, cut two 1.5 lengths of rod.
Note: You will need 3 lengths in the end: 0.25, 1.25, and 1.5, but the leave the
quarter inch piece as part of the 1.25 piece for now.
Using a hex broach and the nylon rod broach plate (ask for them at the tool crib)
in the arbor press, push the broach through each bushing twice to ensure properly
sized openings.
Note: Be very careful when running the broach through the second time to
ensure that the rotational alignment between the broach and the bushing is the
same as before.
Right Angle Gearbox Process Plans Page 3 of 5
Now that your two 1.5 pieces are hex-broached, cut 0.25 from one of the pieces to
give you three pieces: 0.25, 1.25, and 1.5
Gears
Using a hex broach in the arbor press, push the broach through each bearing
once.
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Hex Shafts
Cut your input and output hex shafts from hex rod stock. The exact lengths you
need will depend on your motor placement and output application (Wheels?
Pulleys?). Make your own measurements.
Use a file or belt sander to remove burs and round edges of each cut shaft-end.
Careful preparation of hex rods will make assembly of gearbox much easier.
Gearbox Assembly
Insert large gear shaft through (in order) 0.25 bushing, one side of housing, nylon
washer, large gear, other side of housing, and finally slide the 1.25 bushing onto the
shaft. See picture.
Right Angle Gearbox Process Plans Page 5 of 5
Insert small gear (pinion) shaft through (in order) 1.5 bushing, housing, nylon
washer, and small gear (pinion). See picture.
Note: Nylon washers and pushnuts may be used to secure shafts in place.