Servo horn for Feiyue FY03 metal gear steering servo

thingiverse

Recently I swapped out my son's Feyiue FY03 RC buggy's broken steering servo with a metal gear one, and as the picture shows, it came with horns of different depths - the result being that the new horn snapped due to excessive stress. To create a suitable replacement for the original horn, I designed this new model to be compatible with the metal gear servo while also fitting its unique specifications. To secure it firmly in place, I incorporated a locking M3 screw and nut. The FreeCad .FCStd file is available for personal modification and educational purposes only. Version 4_1 was uploaded on March 19th, 2020, featuring some minor improvements to the design dimensions. However, following further testing, I came to the realization that this horn design was ultimately unsuitable for its intended purpose. The turning torque of the servo's shaft and uneven pressure exerted on the relatively short and coarse teeth led to misalignment issues within the first five minutes of driving. In contrast, the original design effectively addresses these problems with a mechanism that provides a controllable progressive jerk. Therefore, this design is not recommended for use in this context.