Re: roll pin into output shaft
 

Eh, we had a smiliar problem. I broke two of them in the output shafts, but was able to drill them out with a 1/16" bit in our drill press. Of course, I broke a drill bit in the shaft in the process, but a 3/32" bit cleared that out. Once I got the 3/32 bit all the way through the hole, the roll pin fit a lot better; it was still really tight, but I held it vertical with a pair of pliers when i started hammering it. Once it was in far enough I could hammer it without the pliers without it bending, and everything went smoothly from there. It took a lot of time and frustration and a little bit of blood, but that guy isn't going anywhere now.

Re: roll pin into output shaft
 

Part of the problem is that the roll pin is .100 (or thereabouts), and the shaft hole is about .080. Now the BOM for the Toughbox states that roll pins are 3/32". That correlates to .09375. So firstly, the Roll Pins are oversized from the appropriate dimensions. Secondly, the holes are undersized from a proper tolerance perspective of an interference fit with those materials. A proper fit for a split or spring type pin should only interfere a few thousandths, not 15-20 thousandths. Another reason to doubt the quality control folks.

Re: roll pin into output shaft
 

Part of the problem is that the roll pin is .100 (or thereabouts), and the shaft hole is about .080. Now the BOM for the Toughbox states that roll pins are 3/32". That correlates to .09375. So firstly, the Roll Pins are oversized from the appropriate dimensions. Secondly, the holes are undersized from a proper tolerance perspective of an interference fit with those materials. A proper fit for a split or spring type pin should only interfere a few thousandths, not 15-20 thousandths. Another reason to doubt the quality control folks.

Re: roll pin into output shaft
 

We had the same problem. We got one pin in, then bent 5 more (there are 2 teams at our school so we were using all of our pins up >.>) We bought some others from the hardware store and ended up drilling out one side of the shaft and put in our new ones, and now we have 4 good gearboxes. It was one hell of a time waster though, we must have spent three hours last Saturday on them.