WL Toys 104001 Spur Gear Adapter
Description
Spur gear adapter for the WL Toys 104001 buggy. This design is inspired by the following YouTube design: https://www.youtube.com/watch?v=8_8llcORAPQ Feel free to purchase their design off of Shapeways and support the original designer. The materials available will likely be better than what you may have access to. This is NOT the same design but is similar. I had an earlier revision of my design like the above Youtube video and with the filaments I have available, it wore away in about 2 minutes of driving with a 4 pole 3900 kV motor. With a 2 pole sensored motor, your mileage may improve due to the smoother torque application. This design has been modified for increased keyed feature engagement to reduce the likelihood of stripping. It also has a set screw version to lock it to the shaft better if you run into issues with the "standard" version. The stock spur gear in the WL Toys 104001 buggy is a 70T 0.6 mod steel four piece design. The spur slides over the keyed shaft and then keys off against a roll pin. It is quite heavy since it is steel but is also a less common 0.6 mod and limits your potential gear ratios. This design allows for the use of any spur gear of your choosing (32 pitch/48 pitch/64 pitch). Generally speaking, 48 pitch is very common. This should greatly decrease the overall weight of the spur assembly as well as allow a much wider range of final drive ratios. Items needed to complete: QTY=4 M3X6 button/round head screws QTY=2 M3X4 set screws (if you choose the set screw version) A Kimbrough or Traxxas spur gear (other options may work as well) A pinion of the corresponding pitch 78T or 81T 48 pitch are good options. Stock gearing would be very close to 81/26. You can pre-tap the holes with a M3 tap - but given the thickness of the adapter, you could probably screw directly into the material with no issues. I recommend not overtightening the spur to the hub as it will cause it to warp and not run true. You may need to lightly file the mounting face to clean it up. Similarly, clean up the bearing mounting surfaces with either light filing or a sharp knife. The bearings should press on with minimal force. There is a small 1 mm dot feature on the back face to indicate the Traxxas mounting pattern vs the Kimbrough pattern. It is only off very slightly but pay attention when bolting the spur to the hub. To assemble, slip on the FR spacer and engage it with the roll pin. Bolt the spur gear to the hub and slide onto the shaft. Then slip on the RR spacer. Then reattach the drive cups to the shaft - using a normal threadlock (blue) on the screws. Install the drive cup near the roll pin first and then push down on the drive up when installing the other to ensure a tight fit of all the components. Install it back in the vehicle and attach the appropriate pinion. If you feel significant binding or it is very difficult to reinstall, you may need to tweak dimensions or do some light sanding on the RR spacer face that touches the spur gear hub. One note, if you want to reuse the existing electronics/motor - getting the pinion off the motor can be very difficult. General Notes: This assumes you are able to remove the spur gear assembly, the motor, and the pinion. To loosen the screws on the gear/motor mount, heat them by applying a soldering iron directly to the screws (ONLY ON THE METAL PIECES). This should weaken the superglue/CA that WL Toys uses with reckless abandon on the metal joints. The best method I have seen to remove the drive cups (4 mm set screws) is to remove the spur assembly from the vehicle, and use a heat gun and heat up the drive cup area where the screws are attached (QTY=2). This should weaken the superglue/CA that WL Toys uses on the joint during assembly and allow you to remove the cups from the shaft. For the motor itself, this is not a fun task. WL Toys uses lots and lots of CA on the motor mount screws and pinion. If you feel up to the challenge, use the heat gun method described above on the motor assembly (motor, brown aluminum mount, and pinion). I cannot guarantee that it will not damage the motor as it may take a LONG application of heat to get the screws to loosen (both on the mount and the pinion). Take your time if you want to save the pinion. I got a bit impatient and stripped the pinion screw which required me to cut it off with a rotary tool to save the motor mount. If you are concerned with your handiness to do any of the above, purchase back up parts before you start online. For the actual printed parts, this is designed for the tolerances I have experienced with hole shrinkage. It is intended to be relatively tight to the shaft so gently clean out the hole and push onto the shaft. It may take a couple of times to get it to slip on the shaft. If it is loose to the shaft, it will wear it out.
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