The Ultimate Prop Launcher

    PLEASE USE THIS UPDATE, AS THIS MODEL HAS BEEN UPDATED. 

                      If you do not use this update, it will not work.

The update fixes the problem with it being WAY to stiff and, frankly, it working at all.

This is like a ordinary prop launcher, but bigger in every way. For example:

• Approx. 1/200 gear ratio.
• The pull cord has been replaced with a hand crank.
• The prop is locked onto the hub until a button is pressed.
• It can fit props with 10 inch diameter.

Best of all it is pretty much completely insane. (perfect)

“Gear1” and both of the bevel gears need at least 4 perimeters.  

Some More Notes:

• All pieces of the prototype were printed at .3 mm layer height. So you don't have to have smaller layer height.
• all of the uploaded objects are in their correct orientation. Do not change this.
• There is a .3MF file for information on supports. I painted support enforcers on the models in the file. So if it isn't in the file, don't use supports, with the exception of the crank axle. Also, DO NOT use the models in this file for printing. They are not geometrically correct.
• The model “Crank_Axle” is a .3mf file. This is for the correct infill and perimeter adjustments. Don't change this, use this. 
• The machine won't really work right if you don't screw it to some kind of table top. There are feet for the purpose.

Two types of screws were used in this design.

1. #4-40, Thread length: 1 inch, head diameter ≤ 5.5 mm. (x4)
2. #6-32 , thread length: .75 inch, head diameter ≤ 5.6 mm. (x35)

The corresponding nuts:

Note: The diameter measurements are taken from flat side to flat side.

1. #4-40, diameter: .25 inch, height: .09 inch. (x4)
2. #6-32, diameter: .306 inch, height: .113 inch.(x35)

Assembly instructions:

The Hub:

Obsolete - see update.

The Crank:

Get the “Crank_Axle”, “Crank_Arm”, “Crank_BevelGear”, “Crank_Sleeve”, and “Crank_Cap” pieces.

Put 3 #6-32 nuts in the “Crank_Axle” piece. It's kinda tricky because there are 3 nuts in a 5 sided shape, but oh well.

Put the bevel gear on one side of the axle. You can't get it wrong because it will only fit on one side.

Then put the crank arm on the other side. You have to make sure to align the screw holes because it will only work one way.

Put a #6-32 nut in the end of the shaft on the crank arm.

Use a #6-32 screw to secure the “Crank_Cap” to the end of the crank. It will screw into the nut you just put in. It is supposed to keep the sleeve on.

Yay, you have completed you second step toward insanity! Congrats.

The Base:

Now take the “Base” and “Base_LowerBearing” pieces.

Put the lower bearing on the bottom of the base so that it lines up with the circle part of the Base. Use 2 more #6-32 screws and nuts to secure it in place. The nuts go in the square holes closest to the screws.

Now take the “Base_ReleaseButton” and “Base_ReleaseButton_Clamp” pieces.

Put the slanted end of the release button into the square cutout of the lower bearing and drop it down so that it is showing on the other side and can move back and forth freely.

Then put the clamp on top of it on the end near the part that says “PUSH POP”.
Use 2 #6-32 screws and nuts to screw the clamp into the base. The nuts go in the vertical slots next to the screws.

Now take the “Gear2_Washer_Bottom”, “Gear2”, “Gear2_Shaft”, and “Gear2_Washer_Top” pieces. 

Lubricate the hole for the shaft in the base and put the shaft in the hole. 

Then put the bottom washer over the shaft and lubricate the rest of the shaft.

Put the gear over the shaft with the small part on top. (the small part is the small gear on top of the big gear.)

Then the top washer.

Note: there is a difference between the top and bottom washers. the top one is .075" and the bottom one is .070".

Now take the “Gear3_Washer_Bottom”, “Gear3”, “Gear3_Shaft”, and “Gear3_Washer_Top” pieces. 

Lubricate the hole for the shaft in the base and put the shaft in the hole. 

Then put the bottom washer (the shorter of the two) over the shaft and lubricate the rest of the shaft

Put the gear over the shaft with the small part down. It should mesh with the first gear you put in. ("Gear2")

Then put the top washer on.

Note: the top washer is the really tall one.

Now take the “Gear1_Washer”, “Gear1”, and “Gear1_Shaft” pieces. 

Lubricate the hole for the shaft in the base and put the shaft in the hole. 

Then put the washer over the shaft and lubricate the rest of the shaft

Put the gear over the shaft. It will only go on one way. It should mesh with the first gear you put in. ("Gear2")

Now take the “Hub_PushPin” and put it in the bottom of the hub assembly.

The rounded side should be sticking out of the bottom of the hub (the bottom is the side with the gear)

Lubricate the circular part of the lower bearing ("Base_LowerBearing") piece and put the hub assembly into it. 

Next you are going to put the feet on.

You will need all of the feet. ("Foot1", "Foot2", "Foot3", "Foot4", “Foot5”)

In the gif, the gears and hub have been hidden for for this step.

Put the nuts in the base according to the screws that will be used to secure the feet.

For the 2 tallest feet, do not put screws in the top holes, this comes at a later step.

There is a nut that needs to be inserted before “Foot4” (the one with 3 screws holes). If you don't, you won't be able to do it later.

Congrats. . . You have completed yet another step towards insanity.

The Lid:

Now get the “Lid”, and the“Base_Crank_Clamp_Bottom” pieces.

Put nuts in the 2 “nut” pockets that will be covered when the lid is put on the base. To help you find them, they are the nuts that will be used for the 2 tallest feet.

Take the lid and put 2 #6-32 nuts into spaces on the other side from the circle cutout.

Now take the clamp piece and put 2 #6-32 screws in the two holes in the middle from the top.

Then put the clamp piece on the lid and screw it down. 

Now put 2 more screws and nuts into the clamp piece and lid.

The green screws are the 2 mentioned at the last step.

Next, put some more #6-32 nuts in the lid like so.

Make sure they stay there. You won't really have access to them when you screw into them.

Make sure you put all the nuts in the base because if you don't, you'll be sorry.

Lubricate the holes in the lid for the gear shafts and place the lid on the base.

Then put the other bevel gear ("Gear1_BevelGear") on top of the “gear1” pole sticking out of the lid.

Screw down the lid. There are 2 screws at the back (the not hub side) 3 near the hub and 2 from those feet that came over the edge.

Take the crank you assembled earlier and put it on the 3 ring clamp behind the bevel gear.

Place the 3 clamps ("Base_Clamps") and secure with screws.

Take the last piece, “Hub_Bearing_Cover”, and place it over the bub bearing and screw is down.

Note: If the 2 nuts in the back fall out it is not really that big of a deal. It works with just 2.

That's it. It's done. It should look like this: