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LXD 55/75 Broken Gearbox Housing Fix

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#1 Tom Stock

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Posted 27 November 2019 - 10:22 PM

I acquired an old LXD 75 with broken dec housing. I'm sure most owners have this problem so I came up with a solution.

 

1) Remove remaining screw pockets from housing with pliers or dremel.

2) Sand with 320 grit so it's flat.

3) 3D print or have someone 3d print new pockets (designed these in Fusion360)

4) Drill two holes with a 1/8 bit, and then connect them to make a slot.  This slot is left out to make printing easier (no supports).

4) Sand flat (larger) surface of pocket with 320 grit

5) Screw pockets into place on gearbox

6) Apply plastic cement to pocket (large surface) and gearbox housing around each hole

7) Press this half of gearbox housing into place, wait for glue to cure.

8) Finish assembly.

 

My .stl file is available here:

https://www.thingive...m/thing:4006405

 

I forgot to take pictures with the pockets glued in place, but you get the idea. I've removed two of the pockets in this photo and sanded flat as an example.

Attached Thumbnails

  • IMG_2844.jpg
  • IMG_2846.jpg

Edited by Tom Stock, 27 November 2019 - 10:37 PM.

  • markb, Prasad and rferrante like this

#2 Prasad

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Posted 27 November 2019 - 10:57 PM

Great idea



#3 Ericco79

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Posted 11 December 2019 - 11:35 AM

This is a neat idea. On my old LXD75 the screw posts were broken, but the holes were still intact. I matched up the threading at the Lowe's hardware store and bought slightly longer screws. Then I took some small rubber gromets, forced them down in the holes until they were lining them like an inner tube, and then screwed the cover back on using that. It worked like a charm. The rubber gromets were bendable enough to let the screw through, but provided enough resistance to hold the screws in place until they were able to get threaded into the metal housing on the case. Something like these: https://www.lowes.co...Grommet/4565083


Edited by Ericco79, 11 December 2019 - 11:43 AM.



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