Servo horn for Feiyue FY03 metal gear steering servo

thingiverse

Recently I replaced in my son's Feyiue FY03 RC buggy the broken original steering servo with the metal gear one. As shown in the picture the horns have different depth with the result being the new horn broken, due to the stress applied. I designed this new horn to be compatible with the original but to fit the metal gear servo. I added a locking M3 screw and nut for fastening. FreeCad .FCStd file available for your personal needs modification and educational reasons. 19/3/2020 uploaded Ver 4_1 with some minor improvements in dimensions. 14/4/2020 update: finally I came to the conclusion that this horn for the purpose I designed was useless. Due to the turning torque of the servo's shaft and the uneven pressure to the relative short and coarse teeth, there was always misalignment in the first five minutes of driving. The original design solve that problem with a mechanism which gives a controllable progressive jerk. So.... this design is not recommended for this purpose.