Improved jig to drill holes through shafts, to attach gears/pulleys/wheels/sprockets

In my video on 3D printed gears I showed a jig to drill holes through shafts, and how you can use such holes to attach gears to a steel shaft very securely, much more securely than with setscrews. In this video I take some of the suggestions left in the comment section of that video to improve the jig.
Files here: www.creonova.nl/improving-the...
Website: creonova.nl
Instagram: / creo_nova

[@supermage2134]

The V shape is such a simple upgrade, but adds quite a lot of utility. Gonna rate the V shape above the drill hole upgrade.

[@antalz]

With circular slots you need 1 jig per shaft size. Without the drill bushing you have to print one upper half for each hole. I rate the drill bushing above the V-slot. Bit of a wash perhaps because both were sugested by the same person.

[@noweare1]

I just normally use glue and a low friction fit tolerance since I seem to end up making small things.

[@antalz]

Glue works well for small applications, though do you have any trouble with glue piling up on one side, causing eccentricity?

[@simpleman283]

👍

[@TommiKomulainen]

My thought was to make the guiding hole in a removable block that slots into the jig; when the hole gets destroyed you only need to print a new tiny block rather than half of the jig. Could even put the bushing in and use one jig for multiple hole sizes. Didn't try, I suspect it might have some extra inaccuracies due to more moving parts.
OTOH then I saw this ua-cam.com/video/8ou-nyVd5hw/v-deo.html which seems pleasingly minimalistic.

[@antalz]

I think printing a removable slot could work, but you need some kind of method to drill bushing still points straight down. Probably some kind of tapered fitting would work out.
That's also the main thing I'm not sure about in the linked video. He appears to eyeball the angle of the drill chuck in the vise, so I'm not sure the hole is properly concentric, in other words does it point straight down? I'm also not sure he can reliably place his jig length-wise along the shaft, for my jig you can index the ends of the shaft against the ends of the jig.

[@user-yg6nq9lw5g]

Hi !
I have an 895 motor with a 5mm shaft. Is it better to use a flexible couple like those in the z axis of a 3d printer or to drill a 2mm hole in the shaft?

[@antalz]

I would try a flex coupler first, I think the torque is low enough they will hold. There are also flex couplers that use a red or orange plastic "spider", those can handle a bit more torque. Otherwise I would use a set screw to connect to the shaft. I would not try to drill into it, it's a hard shaft, a small drill, and clamping a motor accurately is hard.

[@user-yg6nq9lw5g]

@@antalz Thanks for the fast reply. The motor will be loaded at around 100-110w, so I hope the flex couple works

[@omaraissani6255]

Great improvements ! instead of buying those rare drill bushings, i suggest adding a new component that contains the hole. When the hole wears out you only replace this new component as it is smaller it will be faster to print and consumes less filament. you can check my version here:
drive.google.com/open?id=18PshAAUmXQkYukg8Gim2h_ZKjlYMOhfS

[@antalz]

That's a great idea! The drill bushings are quite annoying to get indeed. A lot of places that do sell them also charge high shipping rates, which is rather annoying.