Doug came up with this cool hack to convert the 28BYJ-48 to a four wire stepper. This makes the motor a bit more useful.

I decided to try a gear hack to speed it up a bit. This might be cool for some applications where less torque but more speed is needed.

I almost have it working, here’s where I’m at.

There are five gear pieces. Here they are starting at the motor.

A) The pinion on the motor
B) A pinion and larger gear
C) A pinion and larger gear
D) A pinion and larger gear
E) Gear on output shaft

In a nutshell if you take out B, then move C up one so it meshes with D you’re almost there. The catch is it doesn’t quite read A. But if you take the pinion portion of B (the removed set), it’s the right size to replace the motor gear to complete the train.

What I’m missing is how to attach it to the motor. The motor pinion is long. I tried to trim some of it then heat weld the larger pinion. It didn’t work. But if a method of attaching this gear can be found the output shaft would be a lot faster.

Here’s a look inside.