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<\/a><\/p>\nI put in the radially symmetric features of Deathrunner using my haute usinage<\/em> utility, a rotary indexing head. It’s like my very own 4th axis, if I had a CNC mill where the “C” didn’t stand for “Charles”. Here’s the set screw holes on the motor hub being power-threaded.<\/p>\n The Petri Dish of Motor Mounting (+6) has a slot cut into it in order to pass wires. How did I drill those cool elliptical holes in the center?<\/p>\n Unfortunately not with a rotary broach. I drilled once and discovered that I had transposed two numbers in my dimensions – 0.695 instead of 0.659.<\/p>\n Oops. So I went back over them with a carbide endmill. The extra-large clearance holes won’t affect stator mounting.<\/p>\n All the parts of Deathrunner are prepared. The endcap is my favorite piece of machine work so far.<\/p>\n Look! An assembled Deathrunner!<\/p>\n No windings yet, nor any case screws, just a proof of concept. The case runs true and everything is smooth.<\/p>\n Let’s move on to the drivetrain. Remember when I said I couldn’t find any more 24:1 drills?<\/p>\n Reading back through old \u00dcberclocker build reports of 2008, I remembered that I had purchased two additional 24:1 geared drills for spare parts, but they were never used.<\/p>\n They had to be around somewhere. A bit of excavation in \u00dcberclocker’s parts box revealed the gears of that drill pretty evenly distributed across the bottom.<\/p>\n So here’s the spare 24:1 first stage that I’ll be incorporating into Arbor. That means the fancy\u00a0 2 speed drill hack has been ditched, and I’ll just be making two more Clockerboxes.<\/p>\n Every build report of mine seems to have at least one picture of a pile of drill parts. Here’s this one.<\/p>\n I began parting out the Handiworks gearboxes to use the ring gears and spindles. While I have a reserve of spare drill parts, I decided to use Handis anyway<\/em> because their parts matched<\/em>. There’s no guarantee that any two drills spindles I take out of the pile are actually the same size.<\/p>\n In a moment of inspiration, I used the chain tool as an improvised gear puller. This worked great for the 700 size motors that came with the Amazon drills.<\/p>\n Protoforms for the gearboxen emerge. I popped these off using the Bitch Chuck and some 2″ square aluminum barstock.<\/p>\n The Handiworks ring gears turned out to be different sizes by a matter of thousandths – one was 1.493″ diameter, the other 1.497″. That much difference is enough to throw off a press fit, however, so I actually had to make two different parts. They are paired with their respective ring gears.<\/p>\n Both bearing and ring gear will be secured using the freeze-and-burn method.<\/p>\n … and here we have it, Round 1 of waterjetting for the frame!<\/p>\n Arbor’s frame is all 1\/8″ aluminum plate with selective 1\/4″ reinforcements. This time, the tab and slot puzzle doesn’t<\/em> have T-nuts.<\/p>\n I’m dead set on either zinc-aluminum<\/a> brazing<\/a> or real, legit TIG welding the frame together.<\/p>\n<\/a><\/p>\n<\/a><\/p>\n<\/a><\/p>\n<\/a><\/p>\n<\/a><\/p>\n<\/a><\/p>\n<\/a><\/p>\n<\/a><\/p>\n