Torsen Limited Slip Differential

thingiverse

This is a total rework of the Torsen LSD posted by unotre (http://www.thingiverse.com/thing:356169), with nearly every element redesigned from scratch. The goal was initially to add some tabs for attaching the two housing halves together, but it evolved into a comprehensive redesign. I drew inspiration from the Functional Differential Gear System by Thing-O-Fun (http://www.thingiverse.com/thing:11836) and qsopc's remix (http://www.thingiverse.com/thing:737465). The only components that remained untouched are the worm gears and their mating gears, which were modified to be integral with other parts for easier assembly. I uploaded the source files as requested in Inventor 2017 format. If you have any questions about the modeling or assembly process, please don't hesitate to ask. The parts are assembled using M3 screws that are 8 or 10 mm long. The holes are slightly undersized, so it's recommended to ream them with a 1/8" bit (or 3mm) for through-holes and a 7/64" bit (or 2.5mm) for threaded holes. The assembly support features a place to install a small motor, which utilizes the DriveSpurGear and DriveSpurPinion to drive the differential (http://www.jameco.com/webapp/wcs/stores/servlet/Product_10001_10001_2128219_-1). Alternatively, you can find knockoffs on ebay with different gear ratios. I've installed a motor on the Functional Differential Gear System and highly recommend using one of the lower speed options (higher gear reduction) to achieve more torque from the motor. The differential works remarkably well, so well in fact that I had to add lithium grease to the worm gears to induce slippage. This project was a lot of fun, thanks to unotre for providing the original models. Here are the quantities of parts needed: Quantity | Part ---------|-------- 1 | Housing-Cap.stl 1 | BevelGear-Housing.stl 1 | BevelPinion.stl 1 | PinionShaft.stl 1 | Support.stl 3 | HandWheel.stl 2 | BearingCap.stl 1 | BearingCap-Single.stl 2 | SideShaft_Worm.stl 6 | Worm-SpurGear.stl 6 | SpurDetached.stl 6 | SpurDetached-loose.stl (optional, if normal one has too tight of a fit with Worm-SpurGear.stl) 6 | WormShaftKeeper.stl (or use M3 flat washers) 6 | WormShaft.stl 1 | DriveSpurGear.stl 1 | DriveSpurPinion.stl 0 | Torsen_Assembly.stl (model for assembly aid only) 18 | M3x10 SHCS If any parts appear missing or incorrect, please let me know. There were several iterations of a few parts, and I may have missed one. Print Settings: Printer: Folgertech Prusa i3 2020 Rafts: No Supports: No Resolution: 0.2 Infill: 25% Notes: All parts can be printed without supports. Some of the taller pieces with a small footprint might stick to the bed better with a raft or brim, but I was able to print everything without.