[Greg Needel]

I was wondering why you are bothering to pocket the gearbox so much? Since you said this isn't for a FIRST bot, weight should not be an issue. In which case you are just using machine time you don't need to.

Also have you or anyone else with the models taken a look at the strength of those side plates? As your pocketing seems to remove quite a bit of material. Now I am not going to venture a guess as if those will hold or not as I don't know the wall thickness but generally when you remove 80% + of the material from the side the strength is just not there. Either way you or someone who knows what they are doing should look at this design. The same thing goes for your face width of the gears.

Just remember that keeping gearboxes light is nice, but don't do it at the sacrifice of gearbox performance. If the gearbox will fail it doesn't matter how much weight you loose because you wont be able to drive.