PHOTO FEST 5000

well i got the time to take apart my dewalts finally so i took a good amount of pictures so i remembered how it went back together.. so ill post them here for all who are interested in the dewalts.

First things first heres the rear of the support kit. it supports the motor to the gearbox and the two little insulators stop the brushes shorting out to it, made from 6061 and light as heck.

http://photobucket.com/albums/v357/Cobrarobotics/Dewalts%20and%20motors/?action=view&current=DSC01498.jpg

Heres the rear end of a dewalt. notice the brush mountings there, im sure there garolite like in nicks packs.

http://photobucket.com/albums/v357/Cobrarobotics/Dewalts%20and%20motors/?action=view&current=DSC01499.jpg

Size comparison, these things are in a whole new league to the little 550s you see next to the dewalt.

http://photobucket.com/albums/v357/Cobrarobotics/Dewalts%20and%20motors/?action=view&current=DSC01500.jpg

Diameter comparison. the face plate on the xu1 is barely as big as the dewalt motor alone lol, notice the size of the gears as well. far more sturdy.

http://photobucket.com/albums/v357/Cobrarobotics/Dewalts%20and%20motors/?action=view&current=DSC01501.jpg

Heres the top of the dewalt gearbox. that little plate is really well mounted and required to screwdrivers to prise it off. those little tabs you see lock into the case and this is a similar feature throughout as the ring gears employ a similar mounting method. also to be noted is how light the mount and gearbox is, definitely as light as an xu1 gearbox and this is with a milled aluminium housing. most of the weight is in that hefty motor.

http://photobucket.com/albums/v357/Cobrarobotics/Dewalts%20and%20motors/?action=view&current=DSC01503.jpg

Without the anti-crap plate on (highly technical). 5 steel gears and 5 steel pins about the same size as on the xu1s. note how the ring gear is held in with the tabs and is very secure. again it needed two screwdrivers to remove it.

http://photobucket.com/albums/v357/Cobrarobotics/Dewalts%20and%20motors/?action=view&current=DSC01506.jpg

Without the gears. that green ring gear is also plastic btw.

http://photobucket.com/albums/v357/Cobrarobotics/Dewalts%20and%20motors/?action=view&current=DSC01507.jpg

First stage metal gears compared to an XU1 metal gear. they are smaller but they are presumably better quality metal and there are more of them too

http://photobucket.com/albums/v357/Cobrarobotics/Dewalts%20and%20motors/?action=view&current=DSC01508.jpg

Here is no doubt the most impressive piece in this thing. the first stage gear carrier. this is the underside of it. note that in low gear the teeth on the outside of this gear carrier do not engage (the green gear is raised above the teeth by the low speed locking ring). That gear is massive.

http://photobucket.com/albums/v357/Cobrarobotics/Dewalts%20and%20motors/?action=view&current=DSC01509.jpg

Without the first stage in. you can see here the second stage and the first ring gear on top (green and plastic), the low speed locking ring underneath it and then the yellow ring gear on the bottom. to convert the gearbox into high gear you need to remove the low speed ring and flip that yellow gear over.

http://photobucket.com/albums/v357/Cobrarobotics/Dewalts%20and%20motors/?action=view&current=DSC01510.jpg

Without the first ring gear, the lathed out low speed locking ring evident. Team Delta really put some work into these kits.

http://photobucket.com/albums/v357/Cobrarobotics/Dewalts%20and%20motors/?action=view&current=DSC01512.jpg

The internals include
*First ring gear
*Low speed locking ring
*First stage gears
*First stage gear carrier

http://photobucket.com/albums/v357/Cobrarobotics/Dewalts%20and%20motors/?action=view&current=DSC01513.jpg

Without the low speed locking ring. note the hefty pins, defintely a bonus!

http://photobucket.com/albums/v357/Cobrarobotics/Dewalts%20and%20motors/?action=view&current=DSC01514.jpg

final ring gear flipped over for high speed operation, this raised up both the ring gears so they engage with the first stage carrier. this is what makes it run in high speed.

http://photobucket.com/albums/v357/Cobrarobotics/Dewalts%20and%20motors/?action=view&current=DSC01515.jpg

with the first stage carrier back in. this now engages with the second ring gear. that is some awesome engineering work to get everything to work out like that. my compliments to the designers

http://photobucket.com/albums/v357/Cobrarobotics/Dewalts%20and%20motors/?action=view&current=DSC01516.jpg

in with the gears and the last ring gear, where in 15:3 ratio now!

http://photobucket.com/albums/v357/Cobrarobotics/Dewalts%20and%20motors/?action=view&current=DSC01518.jpg

hope you enjoyed that as much as i did

P.S. the difference in efficiency between high and low gear is amazing. in low gear in needed a pair of vice grips to turn the shaft, but in high gear i can easily turn it with my hand.
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http://www.youtube.com/user/HyzerGlen - Videoooozzz

Excellent report; I now understand how the gear change works . You were luck to get that setup, I just noticed the motor support kit has been discontinued!
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Australian 2015 Featherweight champion
UK 2016 Gladiator champion

The insides of those dewalts are practically the same as my $7 two speed GMC's Just mine dont have those fancy CNC aluminium billets mounts and low gear locks. Those Dewalt motors look like royal beasts! Gotta get me some of those one day.

Nice update, glad to see someone has actually posted the full pull down of these things, haven't seen any robot sites with a complete Dewalt Dismantle
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