pic: Team 948 2-Speed Ball-Shifting Gearbox CAD Drawing

[team222badbrad]

Originally Posted by sanddrag

I tend to think the sliding friction and wear of the gears on the shaft isn't.

So your saying dogs don't wear on the gears either?

Milling the four slots into the gears with a mill bit is easy. Slap the bored out gear on the mill vise, dial indicate it on center, move the table to each slot, and your done. (If you have a digital readout lucky you!)

We do not have access to this wire EDM you speak of!

These transmission can be built with a mill and lathe.

The tolerance is usually about 4-5 thousands. In other words, if your shaft was 1.000'' you would bore the gear diameter out to 1.004'' I do believe we have made that gap as much as .01''