voicecoils wrote:Something I wonder about though, would the stainless be TOO strong? WIth gear to gear contact, something's got to give, ie gears will wear. With the current nylon gears, they will wear before the pinion and sun gear.
A stainless set of 3 gears could wear out the pinion and sun gear quickly, possibly. This could be something to think about...
I don't think you have to worry much about that. I suspect the stainless would be softer than the sun gear and would take most of the wear. Wear should be minimal with decent grease. The metal to metal gear contact in the Heinzmann motors has proven to be long wearing.
Using one metal and two nylon gears may be a good comprimise also.
The shock loading that Knuckles is describing will still be an issue. Too bad the controller doesn't do something to prevent that...
If the gears are super strong, the next weak point might be the freewheel mechanism.
You can get similar shock loading if the wheel loses traction while accelerating and regains traction suddenly, like going over a curb with the throttle on.
One crazy idea I had is you might be able to use a new nylon gear to make a mold out of plaster or something and use it to cast your own metal gears. I'm not sure if there is a casting mold material that will give you a smooth enough surface finish. Brass or bronze would be easier than steel. You may also be able to create your own composite gears using this method.