TIE Pilot Chestbox Gear - Original Trilogy

This file is just about as accurate as is possible providing all the current references to the screen-used items. This is likely the most accurate model available of the gear used on the TIE pilot chest boxes in the original trilogy. The original part has so far not been identified.

The original pieces were in white plastic, and painted gray, likely with the same paint as the rocker switches on the chestbox.

This was intended for resin printers - FDM printers will struggle a bit with this model.

The tooth profile and outer dimensions were achieved using standard engineering formulas used for gear design. A module of 0.1”, tooth count of 18, and pressure angle of 14.5 degrees resulted in an exact match for the estimated 2” diameter of the original, and the standard addendum/dedendum diameters matched with the available photos. This gives me a high level of confidence that the outer profile and dimensions are very close to the originals.

Since the opposite side is never seen, it's been left flat for easier mounting to the chestbox.

The dimensions of the inner features were measured using images scaled to that 2” outer diameter. Ejection pin marks were also added to simulate the injection molding artifacts seen in the screen-used items. There are some details in the inner rings that are “guesstimated” due to the low resolution of the reference photos, but none of these are discernible at arms length, so the overall effect of screen accuracy is still achieved.