ROFI Servo Horn Adapter
Description
Instructions
You will want to print these at least four at a time, to give the layers time to cool off a bit. Once cool, glue them onto the horn perimeter.
You should use a couple of washers to set the spacing on the larger radius. I did not include this feature in the model so as not to require that it be printed from the hollow side. This might make it difficult to fit.
YMMV
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The horns mate onto a toothed gear, usually nylon or brass. It's a very tight fit, and subject to lots of torque. A horn made from ABS would not hold up very well if at all.
Ever tried to print the complete servo horn? Or are the notches in the servo hole to small to print?
I would think that you could make a complete horn, including gear head negative, with a high resolution printer like an R2 (and maybe an R1). The printed horn won't be as strong as molded horns though. I would imagine for smaller loads a printed horn might be just fine.
I'm not proficient in OpenSCAD, so Solidworks is my medium. Maybe I can export a DXF? It's a fairly simple idea though.
Did you happen to make this in OPenScad? if so could you post up that file as well for modification?
License
I've had a chance to try this out now, and I have a change coming later tonight. I got my hands on the right size horns, and I'm seeing that they are "taller" on the servo. Simply using the current part doesn't quite get you there without some additional work. I'm changing the status to Work In Progress until I get this issue settled.