A project I'm working on required that I reduce the overall size of a sub-assembly. I've contemplated modeling and printing RC servo cases in the past, access to an Object printer presented an opportunity to experiment.
I'm using Hitec's HS-645MG servo. I've included my file set at the end of the instructable.
Step 1: Servo Case Modifications
Step 2: Removing the Servo Horn and Servo Case Back
Step 3: Removing the Top Cap, Gear Train, and Bearings
I've also included a shot of all the parts on a post it, make sure not to lose any of them.
Next, pull the bearing off the servo body and push the bearing out of the servo top cap.
Step 4: Removing the Potentiometer and Motor
The motor is a tight fit into the servo body, there may also be a dab of adhesive that you'll need to scrape off with the tip of a screw driver. Don't pull on the motor wires unless you want to solder them back on later.
Step 5: Inserting the Motor and the Potentiometer
Step 6: Attaching Servo Back Cap and Bearing
Press the bearing on the servo body and into the servo cap.
Step 7: Reassemble Gear Train and Attach Top Cap
Wiggle the servo top cap onto the servo, you shouldn't have to force it. If the gear train isn't reassembled correctly the top cap will not fit.