VEX Build Masterclass #4 - Gear Thinning

Sorry to the three gears I destroyed, your sacrifice will be remembered.
Thanks to Ben 515R for recommending me to thin gears using a lathe. Thanks to Joey 4082B and Tyler 4154V recommending hacksawing.

[@tomw5176]

Great stuff, Ryan! Keep them coming!

[@piraterobotics]

nice, we'll have to try it with the harbor freight mini lathe that we have

[@ali-1353]

This is egg chair privilege.

[@cookiezbitz]

Amazing

[@ryan4253b]

go to bed

[@cookiezbitz]

@@ryan4253b im in california

[@ryan4253b]

@@cookiezbitz fair, continue staying awake

[@tfninjadoom]

I understand the original vex gears had them, but is there a reason for the protrusions on each end of the gear not being cut off completely? Removing them would create a flat profile on both sides, though to be fair I'm not sure just how much more usable that would make it and there might be a cost in structural integrity trying to break the inner metal insert of the gear.
Additionally, can this be extended to the steel pinions and 24T gears?

[@3818c_cookin]

You would cut into the metal core

[@ryan4253b]

Well, the main reason here is what with this mounting method, it is impossible to fully flatten out the gear face. The lathe would otherwise go through the screw and the gear would likely be damaged in the process. You can flatten out the center using a belt sander afterwards - this would work as long as you do it in short intervals to make sure the metal core don't heat up and melt the plastic.
As you have said, it is somewhat rare where you will need a gear that doesn't have the core intact - you can build a 3 wide drivetrain with the core, and I've personally never needed a gear where the entire face needs to be flattened out. Leaving the core also benefits from the extra stability and the ability to use the new shaft inserts.
This method would also work with steel pinions and 24T gears. Just make sure to go slowly and apply oil as you are cutting through steel instead of plastic.