Dual motor board with cast aluminium motor mounts

Lightweight / Folding / Portable EVs - seats optional
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Jonni   1 µW

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Dual motor board with cast aluminium motor mounts

Post by Jonni » Jan 05 2017 11:06am

Hello, just wanted to say hello to the Endless-sphere community and share my project with you guys!


I made the motor mounts using lost PLA aluminium casting. The motor mounts ended up really sturdy and fit really well in to the trucks.

Highlights of the current setup:
237Wh batteries @ 30V
total motor power 4.8kW
max speed about 45 km/h

Parts list:

Motor mount plates: Made using lost PLA aluminum casting 3D models: http://www.thingiverse.com/thing:1528916 (great intro in to lost PLA casting: https://www.youtube.com/watch?v=0bxOzCgUj_U )
The board: https://www.amazon.de/HUDORA-Longboard- ... B00U2EAEJ6
Wheels: 83mm high center set wheels http://www.hungryhills.de/longboard/rol ... 78a-orange
Motors: Turnigy Aerodrive SK3 - 6354-260kv from Hobby King: https://hobbyking.com/en_us/turnigy-aer ... motor.html
Belts: 9mm wide HTD5 belts from Ebay "HTD Timing Belt 5M"
Motor side belt pulleys: Cast iron 16 tooth pulleys from Ebay "16-5M-09"
Wheel side belt pulleys: 3D-printed: http://www.thingiverse.com/thing:1528916
ESCs: Turnigy TrackStar 1/5th Scale Sensorless 200amp 8s from Hobby King: https://hobbyking.com/en_us/turnigy-tra ... r-esc.html
Batteries: Turnigy 4000mAh 4S from Hobby King: https://hobbyking.com/en_us/turnigy-400 ... -pack.html

Next up is to build enclosures for the electronics and a more wireless controller. The enclosure will be modelled to sit against the bottom of the board really well and then 3D-printed. The wireless controller will be done using two small Arduino clones and a bluetooth link between them.

What do you think about the project so far? Any questions or comments?

chuttney1   100 W

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Re: Dual motor board with cast aluminium motor mounts

Post by chuttney1 » Jan 05 2017 5:31pm

Obviously, this is out of the main topic, but how did you make your forge? I've been trying to figure out whether to go with bricks, insulating wool, or castable refractory and the only place I can get this stuff is Harbison Walker.

Jonni   1 µW

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Re: Dual motor board with cast aluminium motor mounts

Post by Jonni » Jan 07 2017 7:12pm

chuttney1 wrote:how did you make your forge?
I made my furnace following along this build log:
http://3dtopo.com/furnaceBuildLog/

It's a steel barrel layered with ceramic fiber blanket and fire proof cement. I used cardboard pipes to cast the cement in to the ceramic blanked layered barrel.
Image

Here's few more pictures of my furnace build process and first usages:
https://home.egarden.fi/index.php/s/s4tPL1ncm9sW5VD

Also some videos of the furnace usage are on my Youtube channel, e.g.

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s28400   100 W

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Re: Dual motor board with cast aluminium motor mounts

Post by s28400 » Jan 08 2017 2:53am

Very nice build, thanks for sharing! I recently built a home foundry and have been playing around with casting. Perhaps I will give this a go.
Cheers!
My Project Site: https://www.radicalcreation.com
Science may set limits to knowledge, but should not set limits to imagination.

Hummina Shadeeba   100 MW

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Location: sausalito cali..up the hill in front of the cruising club.

Re: Dual motor board with cast aluminium motor mounts

Post by Hummina Shadeeba » Jan 11 2017 5:18pm

very nice. I was looking into doing lost pla to do mounts as well a while back. there's a place near me that has a forge that allows people to use it. Makes it a lot easier. wanted to cast a hanger with the mount attached. was planning to cast with the axle in.
Hows it holding up?

Jonni   1 µW

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Re: Dual motor board with cast aluminium motor mounts

Post by Jonni » Jan 12 2017 1:19pm

Hummina Shadeeba wrote:wanted to cast a hanger with the mount attached. was planning to cast with the axle in.
Hows it holding up?
That was my original plan as well: to cast the whole hangers with the motor mounts built in.

I ended up doing the separate plates for few reasons:
  • it was easier to model the plates than whole hangers
  • plates were easier to print than hangers
  • not sure where I could find strong enough threaded rods to be usable as axles. Even with strong threaded rods the wheel bearings would sit against the threads, not against a smooth axle like in normal hangers. Ideally these would be made using a lathe, but I have no access to a proper lathe.
  • and lastly the casting is a pretty complicated and error prone process already, I would not want to make it even more complicated by having the axles embedded in the sand - plaster mold.

Hummina Shadeeba   100 MW

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Re: Dual motor board with cast aluminium motor mounts

Post by Hummina Shadeeba » Jan 12 2017 3:14pm

sand casting? I see you used plaster in your pic but I'd have thought it would have too many overhangs for sand and you'd have to do the classic plaster around your printed part.

the axle you could use a plain hardened steel shaft and then thread it afterwards as is typical. I found threading an axle is easily done with a basic 5 buck die.

I could send you a copy of a hanger I made on sketchup and it's a clone of a caliber which I think would fit your mount design if you want or you could probably find another caliber design and to try for the whole thing with the axle in! I'd like to see you try it and with nice pics.

Jonni   1 µW

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Re: Dual motor board with cast aluminium motor mounts

Post by Jonni » Jan 14 2017 6:38am

Hummina Shadeeba wrote:sand casting?
The mould was created using a 50% sand 50% plaster mix. The sand makes the mould withstand the extreme heat better than a 100% plaster mould. Check out https://www.youtube.com/watch?v=0bxOzCgUj_U great video for more details: https://www.youtube.com/watch?v=WWVVSZP3Au4
Hummina Shadeeba wrote:I could send you a copy of a hanger I made on sketchup...
I would definitely be interested in seeing your design. Could you post it to Thingiverse or somewhere?

Hummina Shadeeba   100 MW

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Re: Dual motor board with cast aluminium motor mounts

Post by Hummina Shadeeba » Jan 14 2017 12:40pm

the only design I made was the caliber hanger. I'll have to find the one I made but heres someone's that I know from the other forum actually:

http://www.thingiverse.com/thing:1729069

the one I did wasn't finished though as I never figured how to do the rounded shape that fits in the baseplate in sketchup.

if you casted the axle and did a hanger with the mount integrated...that would be slick.

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