Working on the kart again

 Finally retrieved it from MITERS, where it's been hanging from the ceiling for the last six years or so

Prius inverter based motor drive will be the next thing to be redone after it drives again:

Off on an adventure

Why haven't I been building anything?  I was off on an Adventure.

Spinning Drive Unit

 

Slapped a mini cheetah motor drive on there to make it go

Assembled Rotors

That's looking like a drive unit

 

Missing a rotor

Machining a new shaft for the rotor:

Improvised chip deflector for roughing

nice

Other side done

bearing and lock ring test fit

Next to the stock shaft.  Going for a normal press vs the straight knurl on the stock shaft.

I don't own a 2d printer and didn't plan far enough ahead to print the drawing at work, so this happened

Making More Kart Parts

 

Single-point keyway broaching

Ring Gear Machining

Ice Trike

 Dane tricked me into building something dumb

ice skate in a garbage pile at miters

bridgeporting out a skate holder

tires tuds

photo from adi

other dubious ice vehicles

Stator Assembly

 Stators shrink-fit into the housings:

Machining fixture turned into a guide fixture for the shrink-fit operation

Band heater wrapped around the housing to keep it hot while installing the stator:

Borrowed the pneumatic powered hydraulic press at work to make sure the stators didn't get stuck half way down:

3D printed 2-axis flexture kept the stators parallel to the housing but allowed them to center to the housing bore:

Lathe Spindle Motor Upgrade

Motor bracket laser cut and bent from .188" steel by SendCutSend:

Crufted NEMA-56-size Clearpath servo motor - integrated motor drive, plugs straight into single or 3-phase mains.

1:1 belt to the spindle:  

Pile of junk being replaced:

Spin-down comparison vs the original motor from 900 RPM: