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1In general
Along with pictures which you will be able to see in the gallery, as work progresses and the design changes, I will be uploading dated zip files with the latest FreeCad and stl files for printing all parts on a 3D printer. I use Creality Ender 3. Minimal print bed dimensions you need are about 200x200 mm.
Print everything with 0.3mm layers. Print shafts and hips with a brim. One of the gears (driveGear) requires supports. I do not have any ABS however it might be best to print gears with disk breaks out of ABS since they might get warm. Be careful, I've heard ABS shrinks a bit.
If you decide to print a non-final design, there are two problems that need to be fixed. Gears do not have a 45 degree miter. (Use untested gears from BreakerOne_gears_2020-05-27.zip ) Second, when two hips are put together, hips' shafts do not align on the central gears the way I want them.
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2Part counts
Each leg requires the following number of part copies: 1 hip, 2 femurs, 1 tibia, 2 driveGears, 3 endGears, 4 bearingGears, 1 of each shafts. holeTransferPattern can be used to mark holes on the 3.5" Hard Drive plates. Hip is about a 3.5 hour print, gearbox body is about 3 hours, femur is about 1.5 hours and the rest of the parts are under an hour each. All miter gears have a 1.3 mm module. All involute gears also have a 1.3 mm module.
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3Part cleanup
I use a 22 mm hole saw to clean up all bearing holes before inserting bearings. Sand all 3D printed shafts with sandpaper. File the brim with a file. Holes of all gears need some filing with a small round or flat file. Clean up the pin holes with a 2 mm drill bit and screw holes with a 4 mm bit.
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