I can finally call the thing “done for now” after about a month of on-and-off work. It can run in its current condition, and just needs the battery charger (which the company I ordered from conveniently left out in my order for a battery charger).
Things left to do:
- Tuning
- Battery armor
- COLD CATHODES!
Anyway, no Major Build Disasters were logged, which is fortunate. It had its share of problems, however, including misfitting components, random switch shorts, and way too many hot soldering iron burns.
Some final build pics!
One of the hallmarks of my well-known power tool abuse portfolio is “saw-milling”. This involves using a power miter saw, my favorite universal tool, and using it to cut sideways. This involves pressing the piece against a solid backing and making sure it cannot flip upwards (which results in probable bloody injury), then carefully slicing off layer by layer by sliding the piece past the saw teeth. High tooth count compound cut blades do this readily, and I regularly use this method to cut small slots and such. Here, the right side motor cutout is being “machined”.
It fits pretty well, however. The sides are 45 degree approximations of a full circle, which is good enough. This doesn’t support the motor in any way, as the outer can rotates, but functions as a anti-scrape device.
Both plates installed. The right plate also functions as a motor guard, preventing me from whacking it right into something, which would be rather bad.
Of *course* my remaining aluminum is a quarter inch too short to be an undercarriage plate. What, did anyone actually expect it to be right on?
A sheet metal assembly might be created to deal with this.
The two major electronic bits mounted.
Wiring up the back end. Some of the parts are a little tight, but they just barely manage. I also mounted the control board a bit far forward, but not enough to risk stepping on it. Wires are conveniently tied to the many standoffs present.
Enjoy this shot of the water heater. The “switchbox” mounted at the top houses the big power relay and the switch to actuate it. Remember, both red is actually battery negative!
This was the site of probably the most retarded electrical problem I had ever seen. During testing, the battery power somehow got to the ESC while bypassing the switch. It wasn’t a dead short – things kept working just fine if the relay turned on. After testing and unsoldering everything, I more or less got the problem down to the long run of 12 gauge zip wire. Maybe it was a manufacturing defect, but after slitting the wire down the middle with a razor, separating the red and black, things worked just fine.
Therefore, the only valid conclusion is that cutting solves all of life’s problems.
No, that’s NOT ME. Quit asking.
The Splitting of the Paths; or, rather, of the control and power cables. Since the boards are on opposite sides, I routed them early.
Okay, here it is. The Sharper Image Electric X²/2, codenamed “Snuffles” by a lovely lady friend of mine. So… uhh, Snuffles just needs a few more bits and piece to function at 100%, but is fully working right now.
That’s it! With a week left, I’ll be focusing on other things… like…
Let me snap out of build-stuff mode first.
So lets see some tire smoke, blood and body parts all over the road already! Your fans are waiting dude.