Toughbox

Official 2008 Kit of Parts Gearbox

This gearbox is shipped unassembled.

Overall Ratio: 12.75:1

Two optional ratios are available:
Optional Ratio 1: 5.95:1, using the 40 Tooth Output Gear and the 24 Tooth Cluster Gear
Optional Ratio 2: 8.45:1 (not available yet), using the 45 Tooth Output Gear and the 19 Tooth Cluster Gear

Weight of Toughbox: 2.5 pounds

A weight reduction of 0.73 lbs. is available if 4 aluminum spacers (available below) replace the box extrusion and the 50 Tooth Aluminum Cluster Gear (available in mid-June 08) replaces the standard steel 50 Tooth Large Cluster Gear.

Toughbox is designed to accept one or two of the 2.5 inch CIM Motors provided in the FIRST Kit of Parts. Hardware is included for attaching one of these motors. Only one of the 14 tooth pinion gears comes in the purchased kit.

The parts needed to accommodate a 2nd CIM Motor into the Toughbox are available as accessories below (14 tooth gear, 5/16 retaining clip, 2x2x14mm machine key).

Gear specifications
20 dp
14.5 degree pressure angle
4140 Steel, cold rolled


Input Gear: 14 tooth, 0.315 inch bore w/ 2mm keyway Large Cluster Gear: 50 tooth, 3/8 inch hex bore Small Cluster Gear: 14 tooth, 3/8 inch hex bore Large Output Gear: 50 tooth, 1/2 inch hex bore

Output shaft: 1/2 inch diameter 4140 steel shaft, with 1/8 inch keyway

For assembly directions, assembly views, exploded view, Bill or Material, and optional assembly instructions, please download the "Toughbox User Guide" pdf file below.

Downloads

Toughbox User Guide 17-page .pdf file, w/ assembly instructions and BOM
ToughboxAsm 1-page .pdf assembly layout file
Toughbox CAD File (.stp) 1.2mb

Toughbox Assembly Video on YouTube
Toughbox Assembly Video
Be warned: this is an extremely low-cost, low-quality video. It is almost 10 minutes in length.

Frequently Asked Questions

Q: How long does the output shaft stick out from the gearbox plate?
A: 1.66 inches

Q: The 3/32" diameter roll pin is very hard to install. How do we best do this?
A: Put the shaft on a very hard surface, such as a concrete floor. Tap the roll pin into the hole. You may need to create a slight lead-in for the hole. This is a tighter fit than we expected for this hole, and that is why we included 2 roll pins with these gearboxes in the FIRST Kit of Parts.

Q: Do we offer an extended output shaft?
A: Unfortunately, we do not.

Q: What are the two small holes on the polycarbonate mount plate used for?
A: Those are for mounting the gear tooth sensor provided in the Kit of Parts.

Q: What are the threads on the end of the output shaft?
A: 1/4-20

Q: How do we mount the Toughbox to the FIRST Robotics Kitbox Chassis?
A: Innovation First has provided an elegant solution, as seen in this picture.