Yo-clone-oh Dogfighter

[Dadio]

Thrust washers arrived so I'm just waiting on ball bearings and i can make up the rear diff outdrives .

[Dadio]

The latest version gearbox is finished and all as good as i could hope for , more pictures I'm afraid , both proto-gearboxes and all the proto-gears then some shots of the genuine article and my version .

[Dadio]

Now with added Diffy goodness , i still need to finish the outdrives but its all working, i had it running for a few minutes without load , it was a little rough at first but free'd up well . Shown with the genuine one with the white main gear.

[Dadio]

I got the slots cut in the rear diff outdrives today and made most of the front spindle but that's probably going to be it for this month , I have a customer custom airsoft gun build that I had completed with a view to handing it over at the end of the month but the customer has just asked me to fit an incomplete bipod that he found and pistol grip , so I'm going to have make up the missing parts for the bipod and fit this pistol grip first . I did just order one way rollers and little flanged bearings for the front drive hubs , the square hubs themselves will be easy to make , I can probably quite easily modify some rear axles to fit and I have spare pair of genuine rear drive shafts , that just leaves the front axles and drive shafts and the roll over bar .

[Lonestar]

I'm not saying much because I'm speechless, frankly

[XLR8]

Amazing, Dadio, simply amazing. You have mastered the art of 3D print, that's for sure.
Please send me a PM if I can assist with fabrication of the metal parts - especially the roll-over bar.

[Dadio]

I'm not sure what way to go with the roll over bar , I fabricated the big original style ones before but I fancy something different this time , either the RPS version or I'm really tempted to do a Delta look alike printed version , not sure.

[Dadio]

While I'm tied up airsoft gun smithing I'm printing off an ABS gearbox and a few other parts that are currently in PLA , hoping to get back to this soon .

[Dadio]

Front drive spindle finished .

[Dadio]

A frustrating evening , I finished printing the gearbox shell in ABS and went to try fitting it but alas its not to be so easy ,the tolerances I'd built in to allow for holes shrinking in PLA meant that all the holes were too big in ABS , particularly the bearing holes , that was a pain but not too bad , unfortunately the shrinkage that does happen with ABS has made the gears mesh too tight ! I'm going to order an all metal hot end so I can print nylon for the gears and try the nylon gears in the ABS box , it seems a shame to throw it out as it came out so well .

[GoMachV]

I’d keep your files for pla and copy/edit them for other materials. That way if you had someone like me that wanted a shelf art car it is already set for pla

You may also want to send a couple pieces to shapeways as you have already drawn them and check the shrinkage. It may be closer to what you would want for sla printing. Just keep track of what you have to adjust for future drawings.

[Dadio]

I'd already thought to ask Shapeways about their tolerances for holes but not overall shrinkage , I guess I've learnt something so its not a complete loss , I was almost tempted to print off some ABS gears to see if they shrink proportionally and fit the ABS gearbox but its kind of a waist of plastic as ABS is probably a worse gear material than PLA .
I've got a Micro Swiss all metal hot end ordered so it will be fun with Nylon soon .

[Dadio]

I’d keep your files for pla and copy/edit them for other materials. That way if you had someone like me that wanted a shelf art car it is already set for pla :mrgreen

I'm planning on test running the all PLA gearbox at some point just to see if it lasts all all , I can't see the case failing but the gears might melt

[Dadio]

Found a little time to modify some Scorpion re re rear axles to make front axles , these will hold the roller hub on with a regular nut rather than a C clip , i had to first anneal them then turn them and finally harden them again , i also had to insert a 6mm drill bit shaft into the cup so i could hold them in the lath chuck without squashing them but it all worked out and with only slightly frazzled nerves
Shown with an original thats much lighter in colour .


Next will be to turn and mill the square drives for fron and back , I've got the one way bearings for the front and I'm expecting the little flanged bearings that go either side to arrive tomorrow .

[XLR8]

Very clever Dadio. It's amazing how similar those Kyosho axles are to the originals.
You seem well on your way to assembling a completely scratch-made Dogfighter.