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Oscillator gearbox gear repair  Rate Topic 
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 Posted: Fri Nov 20th, 2020 03:02 am
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Dennis Long
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Earlier I posted that I was looking for a replacement gearshaft/gear for a Samson 1406-N fan I have.  Unfortunately, I had no responses. I also contacted Antique Fan Parts, but they did not have the part either.  So, now I'm considering repairing the gear by replacing the 4-5 missing teeth.  The teeth are not metal - they're some sort of hard plastic-like material. My idea is to take a dremel "cutoff wheel" and "drill bit", to dig out and form a narrow trough under each missing tooth.  Then make replacement teeth out of appropriate gauge sheet metal. Apply epoxy glue to the bottom edge of each tooth and wedge each tooth down into one of the troughs. Has anyone ever attempted something like this?  Any other ideas on how to "fix" this gear?  I've had my eye out for a donor fan, but these are hard to find.  The fan and gearshaft/gear are shown below.








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 Posted: Tue Nov 24th, 2020 11:48 am
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Stephen Miller
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 A good machinist could easily make you a new gear . You need to find a manual machinist. 

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 Posted: Tue Nov 24th, 2020 02:34 pm
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David Allen
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As Stephen said, the best bet will be to take that to a machinist who specializes in small parts. There is enough remaining of that gear for him to be able to set up his equipment to cut the gear. Be sure not to completely allow the gear to crumble or nobody can recreate it.

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 Posted: Tue Nov 24th, 2020 06:16 pm
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Jim Kovar
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Dennis Long wrote: ...looking for a replacement gearshaft/gear.   ...I've had my eye out for a donor fan,...
Many of these fans have rotting,
falling apart wings and were
taken out of commission.

Hopefully not thrown into the
trash heap!

Surely, someone has a donor
for you.

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 Posted: Fri Nov 27th, 2020 05:41 am
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Dennis Long
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I appreciate all the input!  I attempted my original idea in my original post (Plan A), but when I cut the troughs, the material between the troughs fell off the gear leaving a gap (see below). I then had Plan B, C, & D ideas, but before I started on Plan D, my son suggested getting the part reproduced on a 3-D printer. Turns out that's pretty expensive (got $200-$500 estimates), but I was able to locate someone off Craigslist who knows how to do that (he actually teaches 3-D printing & CAD), who said he'd do it for $75.  So, I took the original gear to him to reproduce. He said the new gear would be ABS plastic, but he could recreate the gear in nylon (extra $10), which he said was the material used with the original gear. So, I went for the nylon version for originality and better strength.  Anyway, I wanted to report what has transpired since my original post.  He said he could have it done before Christmas.  Once I get it, I'll post back here with a picture and a report on whether it works as expected.  Don't know what a machinist would have charged, but the 3-D guy already has my part, so we'll see.



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