Outboard to brushless conversion...

Boats, Jet Skis, Kayaks etc., including hovercrafts
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Infinity   10 mW

10 mW
Posts: 21
Joined: May 07 2013 11:16am
Location: Estonia, Tallinn

Outboard to brushless conversion...

Post by Infinity » Aug 21 2013 3:23am

I wanted to make the conversion as cheap as possible. First I used turnigy C8085 180kv motor (because it is cheaper than C80100)and Alien's 250a esc. I mounted the motor directly to the mounting plate where the old motor used to be and connected shafts with shaft coupling which I got from ebay. I used two lead 12V batteries in series to power it (24v total). On the test drive I found out two things: 1. The speed was enough for me (about twice as fast as I can paddle and lot faster than trolling motors) 2. The motor overheated in seconds, drawing only about 40A at max throttle. Actually there was something wrong with the motor and I send it back to be replaced with C80100 130kv.

Now I have been trolling on the lake for three times with new the motor and it works fine. Nothing gets hot hot any more. It is actually faster with the new motor. Max speed is 7km/h measured with gps. The inflatable is quite heavy with me, my friend and all the gear I have on board.

Here is list of items I used:

Johnson 4W76M Outboard. Got it from local auction site for 25€

From http://alienpowersystem.com I bought:

Motor: C80100 130kv
ESC: Alien 250A 3-8S Car ESC
Alien Throttle interface 0-5v: for connecting e-bike throttle to rc esc

From Ebay:

E-BIKE Twist Throttle http://www.ebay.co.uk/itm/281021468169? ... 1497.l2649
I removed the spring that returns throttle to stop, now I can set my speed and start fishing with out holding throttle...

Rigid shaft coupling: http://www.ebay.co.uk/itm/290901780390? ... 1497.l2648
This coupling bore is bigger than my motor shaft so I had to make bushing from pvc pipe, to make it clamp firmly on the shaft.
Attachments
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Last edited by Infinity on Dec 14 2016 9:23am, edited 5 times in total.

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Bazaki   10 kW

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Joined: Dec 25 2009 6:29pm

Re: Alien Power System... Outboard completed

Post by Bazaki » Aug 21 2013 1:50pm

Well done ! Very nice. No imbalance at the shafts I believe, because it sounds good !! :D

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Infinity   10 mW

10 mW
Posts: 21
Joined: May 07 2013 11:16am
Location: Estonia, Tallinn

Re: Alien Power System... Outboard completed

Post by Infinity » Aug 21 2013 11:53pm

True, balance is almost perfect. I tried to drill the motor mounting holes very carefully and I think that the motor is centered very well. But there is slight vibration. I think it is from unbalanced prop and gearbox. On water I can only hear motor high pitch noise. It doesn't scare fish when at trolling speed. And I know that cause I have all ready caught 6 pikes. There isn't much pike in that small lake.

torqueboards   100 MW

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Re: Alien Power System... Outboard to brushless conversion

Post by torqueboards » Aug 30 2013 8:30pm

That is a smart idea since boat motors are pretty expensive. Awesome!
DIYElectricSkateboard.com Electric Skateboard Kits

exco   10 W

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Joined: Feb 19 2011 8:26am

Re: Alien Power System... Outboard to brushless conversion

Post by exco » Oct 12 2015 10:04am

Congrats. Also on documenting the build here.

Try a coupling with some flex like this if you're having problems with the rigid one.
K2 kickboard build thread (63mm, up to 3kw) | cad files on github
Backfire LRS build thread (GNG "450W" mid drive) | cad files on github

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