Quote:
Originally Posted by GeeTwo
The form factor, including the mounting, is the only real difference. If you use a COTS shifter, use the recommended cylinder. If you're building your own, managing space is the deciding factor.
It depends on how much pushing you're doing, and (more importantly) how hard the collisions are. The case where you're most likely to need steel is on the bull gear (gear nearest the wheel) and the gear that engages it. It would take a truly extreme case to require steel gears in the earlier stages, or even on the bull gear for simple pushing without collisions.
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I second both these statements. I think the first stage in the gearbox is a great place for for aluminum gears.
One thing I've toyed with, but never implemented is the idea of removing material from the body of a steel gear to compensate for the weight differential. The strength of the individual tooth is really where the material decision has to be made. There are tools to make those calculations available.
In my FIRST career there are a number of things I've been conditioned to avoid because of bad experiences (none of these specifically from the three cim ball shifter situation discussed within this thread)
Aluminum gears, cantilevered shafts, and #25 roller chain are standouts on that list.