[marccenter]

Dear CD,
I appreciate Clinton and Tim-tim comments. Here's some modifications based on your input. 1) Added rubber shim to better align the CIM gear, 2) Added holes to allow addition of encoder mounting plate, 3) Added numerous holes in side plates to facilitate potential mounting locations. 4) One extra long shaft plate is a piece purchased from Andy Mark that can be shortened by the end user.

I also added 60T Hex Gear (VEX) as last stage rather than 50T. I was able to move the entire assembly 1/4 inch and still have everything remain in the 4 by 8 size limit. The final ratio is now (50*50*60)/(14*14*14) = 54.7 vs 45.6 (50^3)/(14^3)

Comments: 1) Even though the hex bearings are double the cost ($4 vs $2), my design goal was to minimize machining operations associated with the hex shafts (not designed for production). This way, someone can build the entire gearbox without machining the hex shafts, with just the 2 water jet cut side plates and purchase of gears and hex shafts from Andy Mark and/or VEX Robotics in their home garage where mine was built.

I'm still learning and having fun at it!