Introduction: Santa Rebuild

By Things
About: I am an author and a maker. My current project is Santa's Shop. I'm working on a science fiction type book--more later. @EngineerRigsby

Santa and the elves (animated characters going into their seventh year) are ready for new servo motors.

The servo motors, having logged in more than 700 operating hours, are not reliable. Elfis has swatted a train off the track. Elsie has broken Elfis' guitar. Elmer has demonstrated a violent twitch. Santa has given up pointing. Thirty two servo motors (eight per character) need to be replaced, but EXACT replacements are no longer available. Failures tend to occur in the feedback pot and the motor brushes--replacement parts are something I just can't find. New motors are a bit larger and more "standard" looking. I'll get several spares and hope that these are more universal for future repairs.

Supplies

32 Robot Servo assembly

Step 1:

This is the head/neck mechanism. The new bracket is 4mm longer than the old.

Step 2:

Sadly, the new bracket will not fit inside Santa's head.

Step 3:

Using a soldering iron (heated to 500 degrees F), I carved out a bit more space inside the head.

Step 4:

The new motor assembly is slightly larger and does not have the side grooves of the old motors.

Step 5:

I designed and printed a custom 3d bracket to support the neck motor.

Step 6:

The new neck/head assembly is placed in Santa's upper torso.

Step 7:

I used duct tape to secure the motor in place (the old motors slid into grooves within the torso).

Step 8:

The old arm assembly had to be removed.

Step 9:

The new motor, because of the shaft on the backside, does not fit inside Santa's shoulder.

Step 10:

A hole (1/4" diameter) had to be drilled in the shoulder socket.

Step 11:

A special bracket was designed and 3d printed to mate the hand/arm to the motor mechanism.

Step 12:

The arm assembly is placed inside the shoulder socket.

Step 13:

Custom printed spacers help to hold the assembly in place (in the grooves that the old motor used to slide into).

Step 14:

Servo wires on the arm motors are tied together so they will not get pinched.

Step 15:

Duct tape is used to secure the arm assembly to the shoulder.

Step 16:

Hopefully, Santa will have a few more years of trouble free operation!