Yesterday, the new aluminum pulleys arrived. Today, I went here and had them turned and drilled to taste. The screeching cacophony of ripping, tearing metal reverberates through my tingling ears. It could have been solved with a dose of cutting fluid.
Another step in completion is now over with…well, mostly. The electrical system is going to be really expensive. Here are some pics!
Pulleys and belt from SDP-SI. These are 5mm pitch with rounded teeth, which makes it more awesome. Larger pulley is 60 tooth, smaller is 16, for a total ratio of 3.75:1
Bored out and chopped pulleys. First disaster: I bored the small pulley to 12mm and the motor shaft is 10mm. Not sure where I pulled that number from, and I don’t really want to know. Either way, it will need an adaptor bushing. It would have helped to have the motor along with me during the machining…
Pinhubdrive from the previous update. It’s great when things work out exactly as planned. This thing is so solid (and heavy) that I have no qualms about sticking the full power of the motor to it, even when it is capable of 6KW. I ended up not making a McMaster order for six pins, and instead got some roll pins on the way back. These are probably rated for less than 13,000 in-lb of torque, but they should hold….right?
Other side of the same assembly. The bearings are sunk into the pulley an extra millimeter, since the whole assembly is an extra millimeter wide.
Near perfect fit. The wheel doesn’t rub the motor as it looks, but has a few hundredths of clearance. This is probably enough to get jammed really hard if something gets sucked in, but if that happens I’ll probably be dead already. The frame in front of the pulley had to be cut away slightly because the pulley was too large diametrically otherwise. It’s what happens when you upgrade a pitch.
To do: Find a freakin’ metric bushing, which will be nearly impossible locally. Attach the motor and belt. Make a temporary duct-tape-and-alligator-clips moving platform.
Then buy batteries ($$$), charger ($$), controller ($$), and associated equipment ($). Hopefully I can find some more dollar signs in my junk pile.
Bot on.