Might be injection but my guess is they are a molded epoxy with some secondary machine work to clean and square things up to proper dimensions. They don’t look like an SLA, which typically would not be very strong anyway.
So how did you get them made and how painful was the tooling, curious minds want to know. 
lol, well I dont share HIS enthusiasm, they look good. 
awesome !!!
personally i like the 6 cannon tank as much as the tracked walker
Why green Ev, why??? 
I wouldn’t bother making an injection mold unless I knew the design was good. These are made from a Fiberglass casting mold and 2-part epoxy resins. They are actually alot stronger than the original plastic bottom.
I hand carved the original plug from a stock servo bottom and some hardwood to get the shape right. Then I used some tubing guides and a lock nut to make the center mark on the thick part. Then primed and sanded, and sanded some more, and some more, then sealed it and made a thin fiberglass copy. From there I use the fiberglass halves to make my 2 piece solid mold. The hardest part is pouring the resins in and using the guide tubes to keep the lock-nut and guide rod perfectly centered and at right angles. After, the guide pieces are slid out and the lock-nut is embedded in the case.
These brackets are unfinished. I haven’t sanded or polished them yet. They don’t looks absolutely perfect, but I think they turned out pretty good.
The beauty of these is they bolt right on. The stock o’rings on the screws seat nicely and the large oring around the case bottom fits perfect as well. So it is a direct replacement for the servo bottom.
Next I’m molding a center section of the servo case that has a large opening on the side to mount a heat sink, that’s already made, directly onto the motor. I thought about molding vent slots for cooling in the bottom but I don’t like the idea of the electronics being exposed. I may make a second version bottom that has a heatsink molded into it that sits on the chips for cooling those as well. These parts combined would probably allow me to push the 805’s to 8.4V, close to 500 oz/in for extended periods.
And, yes, they will be available for purchase, as well as all the 1/4 Scale Servo brackets. They will be added to our website today. I’m working on finishing up some orders on a couple other products right now, then I’ll start making brackets and hinges on a per order basis. I have too much other stuff on my plate right now to stock them.
LOL, cause green resins look exactly like the black stuff unmixed. That’s what my supplier told me. I did get a discount on it afterwards.
So now I have 5 gallons of Forrest Green Resins and can’t justify the shipping to put another order in until I use some of it. I’m thinking it may become the official 1/4 Scale Servo color.
I’d be fine with green. I do like the idea of 500oz/in. 
Would the sevo electronics actually take that!? i know a heat sink would help, but 500 oz/in. That’s crazy. 
It could also be used as a super power gear motor for rovers and wheels that use a servo size. There are not many motors short of Maxon that have that much power! 8)
don’t forget that there 1/4 scale, a standard size with that torque, taht would be impresive! And BTW Ev, what’s your web site??
The 805’s can put out 500oz/in, but they heat up. They can put out more than 500 but they blow up. 7.2 V’s seems to be as far as you can push them stock. They get a bit warm under heavy loads. 8.4 would be alot better but they heat up quickly under load. Heat sinks to dissipate heat would probably allow them to run on 8.4V under heavy loads. Any more than that and I don’t think cooling would help.
I’ll give out the website soon. Still trying to get some product we already make up there. And get some of the new ones on. I am only filling past orders right now and not taking new orders as of yet. I’m really busy and don’t want to promise people stuff I can’t provide in a reasonable amount of time.
by the way, these brackets will only be available until lynxmotion releases their 1/4 Scale brackets. It’s not my place to say when that will be but Jim gave me the go ahead to sell these. He calls the shots on the brackets since the business would be coming from his customers off his forum. Don’t expect lynxmotion perfect though. These brackets are hand made. They are straight and accurate but they are not CNC machined or computer cut. So they won’t have those perfect edges that the SES brackets do.
I’ll PM you the address for now but keep in mind, it’s in mid-construction. My website designed backed out and moved on me at Christmas so I had to design the site and write the HTML myself. So it’s coming along slowly. I hope to get a web manager soon to run the orders and help out with other aspects as well.
OpenServo gear might help a lot more than you think. Not only can you push higher voltages, I’m not sure if the 805 controllers are FET based or bipolar. Bipolar transistors dissipate a more heat. If the motor itself can take it, OpenServo boards can push it as far as it will go (30V 6A if I’m recalling correctly). I actually ordered some 805s for OpenServo conversion, since I thought it would be easier (they’re bigger) and cheaper (if I mess up) than trying it on one of my 5955s. As soon as I get the parts, I’ll let everyone know.
Linuxguy… one word “DUH!”
Which reminds me, I still need a photo of the circuitboard of one of those (and off to stop hijacking…)
Anyway, 500 oz-in of torque is good. Going open servo will may improve that, although heat will still have to be dumped. This would probably be best done with a cast and machined metal body. Of course, now that we’ve taken THIS much effort, might as well see if we can snag a decent pot, an equivalent gearing system, and we’ve built a fully custom servo set. I seem to remember Jim working on this (wonder if he’s gotten his boards yet from Robotjay).
I very much like the way that bottom casting came out, but I’m still wary of using the motor bearings themselves to support a radial or axial load. I blame my job experience on this one. You just made them, so I wouldn’t say they’re strong enough yet until you get some testing done. If strength doesn’t hold out well, perhaps a thin layer of epoxy and then some very light Fiberglass layers to act as a high tensie strength core would reinforce it well. High end limited edition cast parts for prototypes, good quality injection molded parts for everyone else.
The servo case bottoms will be more than strong enough. And there is almost no load on the motor bearings in the servo. All the load falls onto the output gear bearings which are huge. The bearings themselves lare 8X14X4mm. They are massive. And there is one on each end of the output gear.
As far as open servos, the stock brushed motors in the servo won’t take 12V for very long. One could using a 3=phase controller on an open board with a brushless motor for some insane speed and torque but that would be complex. And once you are machining new metal cases, replacing motors and boards, you really should look into metal gears. And at those torques, you would wish it was digital.
Anything more powerful than this and I would go to motion control servos and industrial servo motors with integrated controllers and drivers.
I remember you mentioning this. I’d be interested to hear the results. I’ve heard these boards are hard to come by. Mind me asking where you got them?
you should keep in mind that the motor itself might object to a significant increase in voltage as well. as with over volting brushed motors for r/c planes you might seriously shorten the operating life of the motor if you drive it too hard.
There are at least two guys on the Open Servo site who are selling Open Servo boards, and robotjay will assemble them for a small fee.
8-Dale
I’ve put some thought into what I could do with these.
5184 oz/in (27ft/lbs) of torque for $524 a pop.
And here is an all metal (case and all) 690 oz/in 1/4 scale servo for $200.
If I did my calculation correctly…
Weight about 0.5Kg…
Torque of: 360Kg.Cm…
Speed: .60 at 60degree
Speed is a bit slow, but I guess you have to trade that for torque.
It’s pretty cheap consider the power it gives you.
I can build a live size robot with that!!!
evo ,could u run the output shaft all the way thru the case?,if so how hard would it be too do ?
No. The output gear on the top sits directly ontop of the Pot. The sahft would have to travel throught he pot which isn’t possible. It would be overkill anyhow. These servo botoms and the stock output shaft and BB’s will support more torque than the servo could ever provide.
