[MrForbes]

Tonight at robot building we were staring at the caliper that was measuring the plastic ring on the FP motor....I was wondering how we were gonna make that funky sized hole with the limited equipment we have available. Then I realized that the orange plastic ring is approximately .040" smaller than 7/8". Since we have to drill a 7/8" hole for the bearings to hold the output shaft, we could drill a 7/8" hole for the motor too, and shim it with a strip of .020" thick aluminum (which we have). This will also let us adjust the gear spacing, by stacking two shims on one side, if we get the spacing wrong.

If this all works, I'll be sure to post some pictures. We're planning to use Lexan plates about 3/16" thick to make the gearbox, and 3/4" long standoffs to hold the sides together.