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Originally Posted by AustinSchuh
how much clearance should I have between the dog's other set of teeth and the other gear?
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The constraining point of this would be the length of your pneumatic cylinder stroke. Typically dog shifters use a .75" bore 1" stroke cylinder. You should design it so the dog is fully engaged when the cylinder is fully extended and fully retracted. As for the clearances, space of the neutral gear, you want to minimize it as much as possible. Assuming that your dog is at least engaged half the gear thickness on both sides I would figure out the minimum spacing by calculating the throw of the cylinder and the thickness of the width of the dog. I would have no more then .125 clearance, shooting for about .0625, remembering that the larger the clearance the less engagement with the gears you get on the dog.