Window Motor Coupler - Alternate Materials?

[Team4014]

We've been trying to find out if the window motor couplers (here on Andymark; it looks like this, but has 6 holes around the perimeter, and came in the kit of parts - the PN is Denso-6) are available in any material other than plastic, and if they are, where to buy them. We're trying to get them in aluminum or steel, and we're hoping that we can order them online rather than having them custom made at a metal shop (we don't have the right equipment).

If anyone knows where we could buy these in aluminum or steel, please reply to this thread. Thank you!

[IndySam]

My question would be why do they need to be made out of metal?

[DonRotolo]

Indeed. Remember, the big gear inside that motor housing is plastic - it will likely break before those black plastic couplers from the KoP would.

That being said, one think we have done in the past is to 'drill' out a metal bar (tube) just big enough so it fits over the motor output gear, and then use a setscrew to hold it onto the gear. If you are careful, it doesn't wobble much.

[Oldbikerider]

I'd also question why you'd need a metal coupler, because it's just connecting to the mating spline pattern on the gearbox output which is only made out of plastic. If you need to connect the coupler to another larger component you could bolt the coupler to an adaptor hub using the existing holes. That way you don't need to machine the complex spline pattern.

Team 3132 is using one of these couplers in our robot this year. It's modified by turning it down on a lathe and other parts are added to it. The plastic spline is a nice snug fit onto the gearbox output spline - it feels strong. And as pointed out above the plastic spline connection will be stronger than the worm and worm wheel in the gearbox.

[mesamb1]

To piggy back on this thread. Our team is looking to order some extra of these couplers(ours is currently epoxied onto a broken window motor). But the only ones I can find are first choice only on andy mark, and there doesnt seem to be any past threads with a link to where to get some any where else. Any one have some advice?

[techhelpbb]

Can not help you find the FIRST couplings. However I made winches for a climber prototype by heating the metal output cog of a window motor to 275 degrees Fahrenheit with a propane torch and pressing a 1/2 pipe NPT bushing with an external diameter of 3/4 PVC. It is actually a little scary just how hard to break that turned out to be. Did that 3x with minimal issue. Though I advise to use a piece of wood to distribute the force on your hands when you heat...press...reheat...press...so on it takes more than 15 cycles.

I bet you could find some fittings or use some proper solvent glue to make any shape output you like.

Obviously be careful.