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By Jerome, May 6, 2010 8:18 pm

A few days ago, I worked on the motor bracket. I also decided to make it bigger. I made is bigger because on the original bracket, I had one of the motor screws that was under a spacer. I had to remove the spacer to remove the screw. Since it is bigger, I have not problem now.

First I had to draw everything on the computer, I printed it to be sure I had the perfect fit. This is the new scooter. Since my bracket is bigger I had to drill new holes in the frame. I took the piece of paper on glued on the frame.

I wanted to be aligned so I turn on my LED flash light.

Here are the new holes.

I did the same thing here, I glued down the drawing and punch out the holes.

Those are the bottom and top of the bracket.

The only concern I have is that I am wondering if I am loosing the natual air flow of the motor by putting the motor bracket right in front of the motor vent holes. I was thinking of drilling holes but need to be sure I will not make my new bracket fragile on the edge.

On the right side of the spacer you can see washers, there are 3 washers, they help me to adjust the depth of the motor so I can aligned the belt.

I am thinking of adding this fan to cool down the motor. I bought this 7 blades turbine fan on hobbyking. It is a little bit big put should do the job. I will need to machine a bracket to hold it to the motor.

I might try other solution like a 5V PC fan.

Today I tested the motor and it works! I test the 30$ motor and at high speed, it was making this very high pitch sound. I will probably need to adjust timing and frequency directly on the brushless controller.

I am concerned about the heat generated by the motor while free running. It was running at full speed with no load for a 2 minutes and it get warm. So a fan will be needed to ensure the magnet health.

Steps before first run

• Add belt tensionner
• Enlarge frame
• Wooden deck
• Throttle wiring
• Attach fan to motor

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By Jerome, September 16, 2009 8:55 am

Here is how it looks all assembled. I had no real problems when I assembled it. Everything fit perfectly!

After testing the scooter, I realise that this beefy motor bracket acts has a heat shrink! I was amazed to see that the heat was transfert to the side of the scooter, I remember the first time I touch the side, it was pretty warm. This pretty good new. I am also planning to have a fan attach to the motor to give better cooling. I am making some fan design to test it out.

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By Jerome, September 13, 2009 11:16 am

To install the motor to my frame, I need a beefy bracket to hold that 2HP motor. I took a scrap piece of 2″x2″ 1/4inch aluminum plate. I made some drawing in autocad to have my template and start drilling my bracket.

A little bit of milling to make every straight.

The 4 screws are the original one that came with the motor. I really need to put some “loctite” so the motor does not fall. Vribation is your ennemy!

To prevent the pulley from moving out, I make a slot in the shaft so I could insert a “C” clip.

Next time, I will test the autocad file on cardboard before making the real part. The mounting hole are not perfectly aligned.