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So,I’ve been tinkering with gear assemblies for a while now,mostly in robotics and model building,and thought I'd share some common pitfalls I keep seeing (and sometimes still make myself!). One big one is neglecting proper lubrication. Gears need the right type of grease or oil, not just any random lubricant you have lying around. I once used WD-40 on a delicate gear train thinking it would be fine, and it quickly attracted dust and gunk, leading to binding and eventually failure.
Another mistake is over-tightening screws. It's easy to do, especially with smaller gears, but crushing the gear or deforming the housing will definitely mess up your tolerances and lead to jerky operation. Similarly, failing to properly align the gears on their shafts can cause excessive wear and tear. Eye-balling it might seem okay, but using shims or spacers to get perfect alignment is worth the effort.
What are some gear assembly mistakes you've learned from the hard way? Any favorite lubrication techniques or alignment tips?