Auger Motor and Gear Box - TechforTrade/Thunderhead-Filament-Extruder GitHub Wiki

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* Denotes that the item is included in the kit.

Image	Name	Description	Source	Files	Qty
	Auger Gear Shaft*		Made	step, drawing	1
	Auger Gear Support Disk		Made	step, drawing	2
	Bottom Plate*	Make from 1/4"x5" flat bar steel	Made	step, drawing	1
	Gear Box Cover	Make from sheet metal 22 guage or similar	Made	step, drawing	1
	Top Plate*	Make from 1/4"x5" flat bar, steel	Made	step, drawing	1
	Auger Gear		Printed	stl, step	1
	Auger Gear Spacer - Thick		Printed	stl, step	1
	Auger Gear Spacer - Thin		Printed	stl, step	1
	Auger Pinion		Printed	stl, step	1
	Flange Bushing 1-2 in ID x 3-4 in OD x 1-2 in long*		Purchased	step	2
	Flat Head Screw 1-4 in by 1-2in long*		Purchased	step	4
	Hex Bolt M4 by 35 mm long		Purchased	step	6
	Nut 1-2 in (kit)*		Purchased	step	24
	Nut 5-16 in*		Purchased	step	4
	Nut M4		Purchased	step	6
	Socket Cap Screw 5-16 in x 1-1-4 in*		Purchased	step	4
	Stepper Motor Nema 42 4120 oz-in*	Available with driver here: http://www.longs-motor.com/	Purchased	step	1
	Tap Bolt 1-2 in by 3-1-2 in long*		Purchased	step	4
	Washer 1-2 in*		Purchased	step	2
	Washer 5-16in*		Purchased	step	4
	Washer M4		Purchased	step	12

Item No.	Image	Name
1		Allen Key 1-4 in
2		Hammer
3		Pipe - short piece
4		Screwdriver Phillips
5		Vise
6		Wood block
7		Wrench 1-2 in
8		Wrench 3-4 in
9		Wrench 7mm

Go to Making the Auger Motor and Gear Box Parts for information on how to build the following parts:

• Bottom Plate
• Top Plate
• Auger Gear Shaft
• Auger Gear Support Disk
• Gear Box Cover

Step 1: Bolt the gear support plates onto the gear using M4 bolts.

Step 2: Press the auger gear shaft onto the auger gear.

Step 3: Place the auger gear spacer onto the auger gear shaft just above the gear.

Step 4: Place one 1/2 in washer from below and 3 from above onto the auger gear shaft.

Step 5: Press a brass bushing into the top plate so the flange is on the bottom side. Use a bench vice and a short piece of pipe. While closing the vice, place the short piece of pipe behind the hole to keep the vice jaw from pressing on the back side of the flange.

Step 6: Attach the motor to the top plate using four 5/16 in (or similar size) socket cap screws. Only tighten finger tight as the motor will be moved into position later on. Also note that you may have to file the ends of the bolts down if they end up rubbing on the auger gear.

Step 7: Press the pinion onto the shaft of the motor using a block of wood and a hammer. DO NOT pound it on with heavy blows. If the fit is too tight, the pinion will have to be filed down, heated in hot water and pressed on while hot or as a last resort reprinted. It should fit snugly so that it does stays in place during use.

Step 8: Press a brass bushing into the bottom plate such that the flange will end up on the inside of the gear box. Use the method described in step 5.

Step 9: Attach the four 1/2 in bolts to the bottom plate using five nuts on each bolt. Tighten each nut as it is added with a wrench. The nuts will act like spacers to hold the top plate the correct distance away.

Step 10: Place the auger gear assembly with washers through the bushing in the bottom plate. Make sure that the square end of the auger gear shaft is on the bottom plate side.

Step 11: Place the top plate with the motor onto the bolts that are attached to the bottom plate.

Step 12: Slide the motor over so that the pinion teeth mesh with the auger gear and tighten in place with an Allen key and wrench.

Step 13: Put the gear box cover in place over the bolt ends that protrude from the top plate and secure with nuts using a wrench.

The Auger motor and gear box is now complete.

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• By Benjamint444 - Own work, CC BY-SA 3.0, Link
• Zephyris at the English language Wikipedia [GNU]
• By The original uploader was SCEhardt at Wikipedia. (Derived from w:File:Schraubenzieher.jpg) [Public domain], via Wikimedia Commons
• By Elke Wetzig (elya) - Own work, CC BY-SA 3.0, Link