Mashined and sanded stainless steel. V2a maybe.
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I had a senior moment and posted the Lego comment to wrong place
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Yep, lasercut stainless steel (v2a), deburred and sanded. The outside with proper module 2, because why not… 
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I see.
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Some more refinement to go for those grommet holes, reinforcements inside need to be cut back 1-2mm for the middle to close snug.
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Installed the new gear last night and adjusted it for a tighter backlash, then sealed the gaps with Sugru Black, lubed the tranny and sealed her back up. Also did anti-puncture tyre liner in the back wheels (sorry no photos).
Tonight I’m cracking open the other GD again and adjusting it for backlash, then doing the front anti-puncture liners, and finally adding the wheel balance beads inside the inner tubes. That’ll be the last mechanical bits.
I’ll do some soldering over the weekend and hopefully finish up the electronics before next week, then tool around on 8S for quite a while before I can buy cells to build a 12S Li-Ion pack.
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That looks too tight? I’m not a backlash expert, but I’ve messed with it a little bit, and that looks too tight to me.
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It clicks when I wiggle it and rolls free, which is what should happen, because the tooth faces lose contact and when they come together again, makes a clicking sound. I’ve literally adjusted it about 1mm, maybe slightly over.
This is why I will never again buy or use any gear in an esk8 unless it’s steel.
The same can and will happen with steel if the backlash isn’t set correctly. Others that did it better than I, have literally thousands of kilometres on the same gears with no visible sign of wear.
It’s just a learning curve, like anything worthwhile.
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Pretty much knew you lot don’t do technical terms too well, so dumbed it down a smidge.
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This thread would be helpful
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Yeah, only I had mine like the just right example and lost teeth, so…
Set the backlash not too tight, if the wheel gear can wiggle just a tinge, it should be alright. Having it too tight might cause premature wear on the wheel gear.
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Mine is now somewhere in between too tight and just right according to that thread.
Also, I’d much rather have some run-in period with slightly reduced life, than broken spur teeth.
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