Jumbo Toyota third Member, Open Differential working model

thingiverse

This is still a work in progress with detailed assembly instructions yet to be fully fleshed out. For use with this housing: https://www.thingiverse.com/thing:2804209 I was playing around with the idea of creating a DIY power wheels type toy for my son and decided to start by tackling a solid rear axle with differential. Deciding that at this scale it would be awesome to make a semi-realistic version, I set out to design something that would meet my needs. It's designed with a few changes in mind. For starters, the vast majority of it was assembled using 5/8 bolts and nuts from a hardware store. The outputs from the center differential are 1" PVC pipe, and I used a threaded rod attached to a long bolt for the drive output. The bolt was glued into the corresponding differential gears at the ends. I glued skateboard bearings in at the ends of the threaded rod and long bolt. The diff gears for both the outputs and the differential were designed to run on 17x30x7mm ball bearings, which I ordered online from Amazon intended for a HPI Baha 1/5 rc truck. The entire axle was printed in ABS plastic. Many parts were smoothed with acetone and/or bonded using a combination of screws, glue, and acetone bonding. The input for the drive gear requires a threaded rod. Unfortunately, I don't have a solid solution for this yet. I used a hollow rod, some washers, a lot of glue, and a threaded rod to drive it, but I'm not thrilled with this solution. I haven't finished my own print yet, so I don't have all the answers or details. It's very much a DIY project!