Replacement hub clamp for a Remex RFD4000 floppy drive
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The hub clamp in my 50 year old 8" floppy drive broke. I made a new one.
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- Creative Commons — Public Domain
The hub clamp for my Morrow Discus 2+2 8" floppy drive broke into tiny pieces. I guess the thin, delicate plastic had grown brittle over the last 50 years. I resolved to design and print a new one, reusing the original spring and ball-bearing.
The Discus uses a Remex RFD4000 drive mechanism. Remex documentation refers to the hub clamp as an "expandable clutch".
I took what measurements I could, but it was hard with the clamp in pieces. I found some of the original patents (US3898814A, US4077236A) that describe (in the weird convoluted language of patents) how the clamp is intended to work. Armed with that knowledge, I created a design in Fusion 360 that seemed about right.
I printed it in PETG (for flexibility), with a small 0.25mm nozzle. Oriented with the fingers pointing up, and with supports around the outside edge. No supports in the center... I used a sacrificial layer to make that printable without supports.
Removing the supports and sacrificial layer and installing the original spring and ball bearing is pretty anxious work; the new one is nearly as delicate and fragile as the original.
But it works: