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Originally Posted by RobDeCotiis
sarahb,
dremeling off the gear only poses a threat to the motor of you're lazy. Make sure you don't get shavings inside the motor and i see no reason dremeling the gear off would cause harm. Cutting into the drill motor shaft slightly won't cause problems, unless you hack it to bits. Some people don't have presses, and honestly, you don't need one. The dremel works fine for removing the gear, and simple expansion/contraction properties of the metals will allow you to put the gear on. freeze the motor(or just the shaft, assuming you have liquid nitrogen in your chem lab  ) and heat up the gear with a blowtorch and you'll be able to get it on, and when it cools down, good luck getting it off. Try to think a little more about reasoning before you post. You yourself have seen the motor ryan put the gear onto, you know it works fine, the motor isn't damaged, i don't really see what the problem is. anyway. beautiful looking gearbox, ryan. nice job 
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As Rob said before, using liquid nitrogen on a motor is a really bad idea. It could damage many parts of the motor, including the cracking the cooling fans or the bush assembly. I would listen to him, considering he knows enough to be a technical moderator of these forums.
Yes, I have seen the motors that Ryan modified. All of them have damaged shafts(lots of little cuts), at least one has shavings in it, and two have damaged bush assemblies. All three were replaced, and I believe the gears from the new ones were pressed off the right way.
Once again I will ask all of you to please stop encouraging other teams to damage their motors. If you don't trust my assessment that Dremeling off pinions is bad, please refer to the numerous other posts that agree, especially the ones by
Paul Copioli, a well respected professional engineer and Unsung FIRST Hero.