Full Undergear Drag Washer

[trond_solem]

I'm not sure the gearsleeve is thick enough to mill the grove in it and still be strong enough.

The grooves will remove less metal than filing down the flats down to the ratchet. There will still be more than enough metal to make it strong enough.

[Keta]

Flats do not create stress risers like a sharp cornered milled grove will, the grooves would be better done with a ball mill.

Here's what I'd make the metal washers like.

[trond_solem]

Flats do not create stress risers like a sharp cornered milled grove will, the grooves would be better done with a ball mill.

Here's what I'd make the metal washers like.

You are right about that.
I was waiting for this comment. :-)
Machining sharp corners in two directions isn't an easy task.
However, two slots are more than enough if you use stronger steel than 316. Round profile on the cutouts and the keys in the washers may even work better than square keys. Just wait a bit and I will run another simulation.

[BMITCH]

Sal, thanks for the info. This will solve my short term problem. In the long term I can't wait to see what the other guru's come up with. All good stuff

[trond_solem]

Well, I was wrong about stress numbers on round cutouts and round keys in the washer. This because of smaller contact areas.
It will still hold up to about 20lb drag on this single washer! That is about 100+ lbs total drag in the system.