[Dave Koller]

Yep looks ROCK solid!! Nice one --

[david85]

Originally Posted by Dave Koller

Yep looks ROCK solid!! Nice one --

Thanks!

Its also completely aluminum so weight is insignificant. I'll get some better pictures after I have the motor on the hoist for the last time. Hope to finish painting everything tomorrow. Engine cradle is done and ready to go back in, now I just have to finish the motor painting.

[gdirwin]

Just curious - why did you add the fan on the motor tail shaft? Is there any natural airflow through the front grill which could be directed over the motor for cooling?

Why did you go for a full frame the full length of the motor (as opposed to a mount just attached to the motor and mounted to the passenger side frame)? It looks like the motor is designed to sit flat on something and did not give you a lot of mounting options... Looks great!

[david85]

Originally Posted by gdirwin

Just curious - why did you add the fan on the motor tail shaft? Is there any natural airflow through the front grill which could be directed over the motor for cooling?

Why did you go for a full frame the full length of the motor (as opposed to a mount just attached to the motor and mounted to the passenger side frame)? It looks like the motor is designed to sit flat on something and did not give you a lot of mounting options... Looks great!

Yes, it was intended to be mounted off the side of the case instead of the end.

I had to wrap the frame around the back of the motor because of the limited options for putting mounts in the car. Much of the area under the motor is wide open. Tying everything together also re enforces things nicely.

The fan came from factory, its visible now because the cover is removed for painting. If it wasn't for the fan, this motor would be quite small compared to the usual warP or ADC motors of choice.

Not much flow through the grill of the car anymore because of the 13 cell battery box that completely blocks off that area.

[RKM]

David,

Nice progress! I presume that is a TEFC motor, thus the external cooling fan? That's one definite advantage over the Warp and ADC DC motors, no worry over water, dust and other road junk getting into the motor. Motor mount looks good also.

You've taken the path less traveled. Looking forward to seeing this one complete.

Rob

[david85]

TEFC = totally enclosed, fan cooled?

However the motor does appear to be very well sealed and the main case is dipped in some sort of plastic coating then painted over (end housings do not have this). I think the idea was for added insulation but not sure. The end housings actually attach using a turned ridge all the way around that is a very tight fit.

This motor has no windings on the rotor, so only the stator needs cooling and that can be done all on the outside. I know one of the reasons for the internal cooling fan with brushed motors is simply to blow out the carbon dust from the brushes before it can cause an internal short (car starters are bad for this). You can blow as much air as you want on a brushed motor, but it won't last unless there is internal circulation as well.

[david85]

Long day, but everything's back in (chassis, suspension, CV shafts, wheels and powertrain). Next will be some modding of the controller to reduce the size of the case. As a little bonus, we had some extreme weight wielding cable lying around thats probably about 5/8" of copper. Sever overkill for a brushless motor, but it comes free and there is enough for the whole project from what I can tell.

I settled on black for the motor. Same as the frame, although looking as this picture from under the car, it seems I missed a spot. Touch it up later. Anything is better then that pale green stuff (I know you were all thinking it!)

[david85]

Uploaded another video. I wind it up a little in this one mainly for fun, but also to see what the shifting at higher throttle settings would be like. Seems to work well. Can't get over how cool it sounds inside the car.

http://www.youtube.com/watch?v=sh3vYP1OlFc

[gdirwin]

Looks (and sounds) Great! Videos are even better than pictures....

When will you go for a drive?

[joshg678]

Make sure you have a co pilot or a mount for the video camera when you do a road test.