Modifying The Staton Gearbox For 5:1 Gear Reduction

5

5-7HEAVEN

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The Staton gearbox has three gearshafts inside. The first connects to the engine's clutchdrum. That shaft's gear meshes with a 5:1 intermediate shaft which then meshes with the output shaft for an 18.75:1 gear reduction.

There is only one output shaft on the older-style gearbox, either on the inside or outside of the box. Then the updated gearboxes evolved with output shafts on the left side, right side, both sides AND where the 5:1 intermediate shaft locates.

Instead of buying a newer gearbox with the 5:1 output shaft, it would seem to be a simple matter to bore a 5/8" hole thru the gearbox left-sidecover. Then you just buy Staton's 5:1 intermediate shaft with 3/4" output shaft for the sprocket.

For that matter, you could bore the opposite side cover at the main output shaft, buy Staton's later-model output shafts and convert from one-side output to dual sprockets. Orrr, converting the outside drive gearbox to inside drive. You could also bore four holes in the left-side cover to remove the engine's mounting bolts. If you own an older-model Staton gearbox, you KNOW what a PITA it is to remove the engine.

In other words, upgrading and retrofitting to Staton's newer output shafts and options.

I had mulled over buying another gearbox with inside drive, especially while dreaming about a NuVinci conversion. This option is WAYYY cheaper than a new box, as the Staton's output shafts are only $29.95. His gearboxes sell for $240-$290.

On paper, it seems do-able. I want to tap off my Staton gearbox for 5:1 gear reduction to run my 100-watt miniature alternator. The dynamo puts out its power at 1,000rpm, so I need to gear it down from my engine's 8,000 rpm spins.

So the BIGGG question is.....has anyone modified their Staton gearbox for 5:1 gear reduction?
 
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K

kerf

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I've been pondering doing the same thing for an inside drive. Hole needs to be a few thousandths over 5/8 could use the bearing with a bushing to drill pilot.
 
5

5-7HEAVEN

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kerf, I'd send it to the machine shop if someone's done it before.

I'll ask Dave Staton. He'll void my lifetime warranty, but heck it'll cost me $100+ in shipping to him anyway.

I can swap parts and repair his gearbox.

There's really not much in there.
 

loquin

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Could you buy a new gearbox cover, as well as the gear with the output shaft? Probably cheaper than sending the old cover to the machine shop...
 
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5-7HEAVEN

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I could ask Dave Staton, but I have a hunch it might be expensive. You can buy all the gears and clutchdrum in the gearbox for $106, which leaves $183 for both covers.

And his shipping absolutely KILLS me.
 
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Happy Valley

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Oh well 5-7, there's a price for living in paradise.

It was 14 degrees here last night which is killing me.:elf:
 
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5-7HEAVEN

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Happy, it's 69 degrees now at 4:55am, with todays high and low temps at 79-63 degrees, respectively. Weather is clear and 56% humidity. It rained quite a bit these past few days, but we needed it.

Many 2-wheel riders here dress in t-shirt, shorts and sandals, no helmet. Crazy fools. I always ride with 3/4 helmet, fluorescent vest, full leather gloves, shin pads and steel-toe boots...and the t-shirt and shorts.
 
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5-7HEAVEN

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This 5:1 output shaft is to spin a 100-watt mini-alternator and power my 55-watt headlight, tail and brake light.

My alternators arrived, and with the proper pulley I should be able to gear it down to 8:1 reduction.

First I need to find pulleys and a belt to apply what seems to be correct on paper.
 
5

5-7HEAVEN

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Staton Said It Could Be Done!

Well , today I asked the man himself, David Staton, if it was possible to retrofit his 5:1 output shaft onto one of his older model gearbox...

He said YES!!

As suspected, ya just have to drill thru the left-side cover and swap in his 16-tooth gearbox cog with extended shaft. No other parts needed except his $26.95 output shaft, and using the existing bearing.

Dave said it was a simple procedure, and he was not interested in selling his side covers.

I'm so happy.
 
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