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Oscillator gearbox gear repair  Rate Topic 
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 Posted: Thu Nov 19th, 2020 10:02 pm
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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 06:48 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 09:34 am
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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 01:16 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 12:41 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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 Posted: Sun Nov 29th, 2020 01:59 pm
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Marce Clark
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Hey Dennis let me know how it works. I need 3 of them lol
Thanks Marce

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 Posted: Sun Nov 29th, 2020 11:32 pm
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Dennis Long
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Marce Clark wrote: Hey Dennis let me know how it works. I need 3 of them lol
Thanks Marce

Hey Marce, do you seriously need 3, i.e. you have 3 Samson 1406-N fans needing their oscillator gears?  I'd be happy to help you out.

I got back the ABS plastic gear today.  Looks spot on, but I still need to test it.  The story has changed some - the ABS gear will be my "prototype".  Only if it doesn't hold up, will I order the nylon (it's a little more cost).  I will report back with an update soon.

Last edited on Sun Nov 29th, 2020 11:34 pm by Dennis Long

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 Posted: Mon Nov 30th, 2020 02:26 pm
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Marce Clark
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Hey Dennis I do indeed need 3 gears. I have 2 Samson 1406-Ns ready to go except they both need that gear lol.
I have a third one waiting to be worked on so I'm sure I will need a 3rd gear.


Thanks Marce

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 Posted: Mon Nov 30th, 2020 09:13 pm
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Dennis Long
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Ok Marce. I'll get back to you after I test the ABS gear.

Dennis

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 Posted: Tue Dec 8th, 2020 02:32 pm
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Marce Clark
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cool thanks

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 Posted: Wed May 12th, 2021 11:52 pm
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Dennis Long
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UPDATE: replacement oscillator gear is available for the Samson 1406-N fan.  It comes made in ABS plastic ($15) or nylon ($30).  I ran my fan for an hour and 20 minutes with an ABS plastic gear, and it ran fine.  Gear is the exact match and includes the same tooth pitch as the original.  The original gear is believed to have been nylon.





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 Posted: Thu May 13th, 2021 08:33 am
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Tom Zapf
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THAT IS TERRIFIC TO KNOW ABOUT.. BASED  ON MY EXPERIENCE IN THE PAST I WOULD THINK THE NYLON WOULD LAST LONGER , BUT KEEP US IN THE LOOP! 

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 Posted: Sat May 15th, 2021 02:48 pm
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Dennis Long
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Hey Tom, you are correct - the nylon gear should be more durable, hence the additional cost.  Nylon is what I will use in my fan, but the ABS passed my hour-long run test and offers a more economical alternative.  The only difference in appearance is the nylon teeth are solid and the surface a tad gritty, as can be seen in the picture below.


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 Posted: Fri May 21st, 2021 02:29 pm
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Dennis Long
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For future reference, if anyone is interested in one of these gears, see this thread:  

http://www.afcaforum.com/forum2/63050.html


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