Pinion gear tight on D shape motor shaft

1

Hi everyone,

Thought it might be gooderer to make a new thread on this particular issue I’m having with 480 motors and pinion gears,

New 480 long motor pinion gear had worked its way off the motor shaft on Sunday, and while attempting to sort that out I realised that the grub screw holding the gear in place went AWOL - All good I’ve ordered some grub screws to suit.

However in the back of my stash I found an Azreals Armory pinion gear that also has a D shaped hole, the 480 motor shaft is also a D shape. Match made in heaven, or so I thought.

The pinion gear is extremely tight when pushing it on, to the point where I can only get it 1 or 2mm into the motor shaft. Is that sort of tightness normal? Should I force it? Could I gently sand some material off the “D” on the motor shaft for a better fit? If so could that possibly throw the shaft off balance?

Thanks

Jug

2

Make sure there is no burrs or blemishes holding you up.

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I’ve had a similar issue before and what Mai said was the cause, bit of excess flashing on one side taken down with a gentle go over with a file did the trick.

Make sure to use some Loctite when you replace that screw too, they are notorious for just vetoing themselves from existence, don’t know how many of my blasters still have theirs from factory.

4

Thanks gents, I’ll have a gander tonight

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5

A bit of heat applied to the gear is always a good habit to get into, expanding the bore size enough to push it onto the shaft and added bonus of “heat shrinking” the gear in place for an extra strong fit. :ok_hand:

6

Sure enough some work with the correct shape needle file did the trick. Cleaned up with acetone and applied red loctite.

Now with the new pinion installed, the motor won’t drop down all the way down into the gear box, it can’t find it’s er… Hole

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Is the pinon too big for the gearbox hole? Or maybe an alignment issue?

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That was my initial reply, but yet have had to go that route being so small.

9

Yep took the pistol grip off, the new pinion gear is 0.5mm too wide.

Safe to file some material away provided I keep it out of the gearbox?

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Did you say that was an Azrael pinion? Go figure they don’t make them standard size :roll_eyes:.

I don’t see why not but yeah be very tame with how much you take off.

Maybe if you got a drill bit that’s the right size you could use that gently.

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I would be very reluctant to remove material from the gearbox as that will mean you need to add material to the motor shaft, to ideally keep it from moving.

I have seen some airsoft boxes that are tight in the hole (gigidy) and the best practice was to take a little material off the outer edge on the pinion gear. tape up the motor to prevent filings getting in, and run it pushing the pinion onto a file or grind stone…

you end up with a pinion like this
image

If it were me though, I would only do that if there were no other pinion gears available. Be far easier to get a new pinion gear that is the right size.

Azraels “perfect” pinion… just another “innovation” that makes little sense and only suits APS and Aztech stuff.

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How does Azreals figure increasing the diameter improves the pinion mesh? It’s a bevel gear ffs. :roll_eyes:

Physics is physics, mechanics are mechanics, and bullshit is bullshit, it seems. :laughing:

Proprietry for proprietry’s sake.

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And the main feature is the larger shaft section with a larger grub screw with a torx head so you can torque it down more.

Funny cause had a mate buy one of their stage 3 everything expensive builds, and it went back twice with the pinion gear off!
Works a treat I guess!

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Yep azreals pinion.

I’ll take some material off the pinion as suggested, thanks for the replies

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15

Ended up doing a little of both, filed off any high spots on the inside of the gearbox hole, then filed off the tips of the pinion gear and it fit well.

:metal:

16

Having some difficulty with the gearbox screeching when adjusting the motor height.

Bit difficult to explain but there only a very small “window” of adjustment between the motor being adjusted too high and too low where the GB will screech. When I do get it set in that small window of adjustment the blaster sounds great, however it only takes a small amount of test firing before it starts screeching at me again.

Would the best course of action be taking the Azrael’s pinion off and trying another?

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Most likely the depth of the cut on the gear sets, which can vary wildly between manufacturers. :roll_eyes:

Double check the shimming of the bevel gear, as if it’s sitting too low it will create the same issues as you are describing.

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Yeah, this :point_up_2: 100%

Almost a certainty that the bevel gear isn’t at the right height for that new pinion.

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Very good chance that the larger diameter of the Azraels pinion means it is too tight on the bevel gear… I always recommend shimming bevel gear to a new pinion… especially if you aren’t changing for the same pinion as the previous one.

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Thanks for the replies :+1:

1 Like