Making a shim for the motor shaft

By , July 8, 2009 12:13 pm

When I inserted the pulley on the motor shaft, there was some little side mouvement. It was not extremely major but I found this simple solution that could of fix this problem fast and it was free.

This sort of slack was due to me machining of the motor shaft. The “D” slot ( D-bore) was the problem.

The solution was to make a shim to go between the shaft and the belt pulley to prevent the mouvement.

motor_shim_shaft_ 001

The coke can makes perfect shim. It measure 0.0035″ ( 0.09mm)

motor_shim_shaft_ 002Very easy to cut and make the shape you want.

motor_shim_shaft_ 004

Making a triangle helps to insert the shim under the belt pulley.

motor_shim_shaft_ 005

motor_shim_shaft_ 006

With this solution, I was able to remove the slack in the belt pulley and the shaft. After a couple of hours on the scooter, I saw the shim disintegrated or simply not there when I remove the pulley from the shaft. It does work for a certain amount of time. The shim took the same colours has the shaft and was extremelly hard to see.

The first time I did not see it and the second time I removed the pulley from the shaft,  it was there but hard to see.

My first rolling test!

By , July 4, 2009 5:48 am

I have been having real problem at home with my internet provider (Bell sympatico). There is one of there router in Toronto that has a problem with my IP. So I can not use my FTP account and I am having problem with wordpress so I can not edit or created any new post. I also realise that I can edit the time I post news. ( Like this one :))

Right now,  I did my first test on my Scooter! That might sound weird since there is no post about my other modifications I made. I will post them after this one.

I went today see the guys at to borrow a 60A brushless speed controller and some batteries. Vamdues is a technical group here at the University of Sherbrooke that build Unmanned Aerial Vehicle (UAV). I also went to see them because they might need a hand to build there new plane.

I have videos of my first scooter and specifications. The batteries they had was a  Thunder Power RC Pro Lite MS 8000mAh 14.8V.

Specifications for Thunder Power RC TP-8000-4S4PL ProLite MS Military Spec LiPo:

  • Voltage: 14.8V
  • Cells: 4S4P
  • Capacity: 8000mAh
  • Max Continuous Discharge: 16C
  • Max Burst Discharge: 25C
  • Max Continuous Current: 128A
  • Max Burst Current: 200A
  • Weight: 633g
  • Dimensions: 29 x 50 x 255mm

This is a very expensive battery. It cost $329.95 USD. I will not use that in my scooter, not for 330$ and it is only 14,8V!

When it was charge the battery was at 16V and my motor can take up to 36V! We only had one single 16V battery on the scooter.  The motor is so powerfull that it can make wheelies very easy! You really need to be gentle on the throttle. I would guest the speed around 20km/h. It was rainning outside so I did not test it with my GPS to see the official speed.

I will edit the video and post it online.

Inside the motor

By , July 3, 2009 7:10 am

This is my first time playing with a brushless motor, I am very intrigue so I had to take it appart. I also needed to change the shaft, so I DO need to look inside.

Here are the pictures.

electric_scooter_2009_-015C-clip need special pliers to remove, it hold the shaft in place.

electric_scooter_2009_-018They was some spacer with different thickness. I guess when they insert the shaft in, the c-clip is not at the exact same place so this is compensate with different spacers.

electric_scooter_2009_-020The helen key on the back has to be remove.

electric_scooter_2009_-022Now you pull everything appart and get this!

There is 14 magnets and 12 coils. I also notice that all 3 wires are very long stripped wire that are twisted into coils. I have no clue is the windings is in Start or Delta. I would guest it is in Delta to provide more torque.

You are probably asking what is about having 14 magnets, 12 coils and what is Delta? Will talk about that in future post!

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