Saturday, March 26, 2011

Foot Drive Prototype Complete

Last Thursday I modified the 2nd wheel and made the pieces for the Foot Drive prototype.

The Foot Drive in its final version will be made out of aluminum square-tubing with one side cut off. But for the prototype, just the two sides will suffice.

Mostly assembled. Still need the belt and standoffs between the motor and wall in front of it. Speaking of the standoffs, the screws I'm using to hold the motor in place are a little too long. Will have to get shorter ones.
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Yesterday I got the standoffs, shorter screws, and the belts finally came. I reassembled the drive with the new parts and did a power test.

Of course I also test fitted the bracket in the foot shell. Good news is it fits. Now I need to order the aluminum tubing so I can make the final product.

As for painting, it suddenly got real cold again so painting is out until Spring decides to stay.


Sunday, March 20, 2011

Return of the Belt Drive

Today I humbly acknowledge I jumped the gun ordering the chain-driven scooter wheels & motors. When I received the chain version, I discovered the chains where the same length as the belts and the wheel axle was about the same as well (though the wheel itself was slimmer). So I got on the Club's forum and pleaded for enlightenment. In a short amount of time I was told to use a shorter belt (was given a size to try) and to replace the axle. I was also given a scooter drive bracket template to use to build my own.

Why didn't I ask for help in the first place? Stupid, stupid, stupid!

So with a pair of smaller belts on order, 399mm instead of the 447mm I bought, I now will try to return all the chain-driven scooter parts. If I can't return them, I should be able to sell them to someone in the club.

So today I went to the shop to try making some modifications to my belt wheels.
Here is a close-up of the brake drum on the wheel hub. The original Razor E100 belt wheel didn't have this part so I decided to try to cut it off.
Closeup of brake drum

Here is that long axle, now off the wheel. It was being held on by the two inner nuts. Once I took off the nuts the axle came right off. In it's place I'll put a shorter bolt of similar diameter.
Removed Axle

The wheel without the axle. The brake drum I discovered is screwed on. I discovered this after I cut it off with my Dremel. Will note for the other wheel.
Removing brake drum

With the brake drum off I used my Dremel to cut off the extra 1/2" of hub. Now the hub is flush with the bearing.
Extra material cut off

I noticed something blocking the axle hole from inside the wheel so I removed the three bolts and the wheel hub became two pieces. Inside was a loose spacer the axle goes through.
Modified wheel disassembled

Next time I'll do the same to the other wheel and build a bracket prototype out of 1/8" MDF using the design given to me. If this design works for me I'll order aluminum tubing for the final product.


Thursday, March 17, 2011

Painting Begins Anew

Today's weather proved to be perfect for painting. The three panels I already started I gave another coat of Satin White. Once they dry I will lightly sand them and give them their final coat. I also took the two pieces I already primed and gave them their first coat of Blue Metallic paint.
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I have just a few more panel pieces to JB Weld and then I will start priming and painting the remaining panels. I could start the main outer skin halves except I don't really have a good place to place them while they dry. Once I figure that out I will start them too.

New motors, chains and wheels on order. Will retackle the foot drive once they arrive.


Monday, March 14, 2011

I Give In

I just ordered the chain version of the scooter motors and wheels. Because the generic belt wheel I got is wider than the original Razor part, and because the belt is too big to have both wheel and motor close enough for both to fit inside the foot shell, I have to admit defeat in trying to make it work. Oh well. Live and learn. I did some reading today at and other people have said not to bother trying to get the belt version to work without the original wheel.

So now I have two motors, two belts and two wheels I cannot use or return. Drat. Well I know there are other people who use the belt motors (they have the original wheel). Maybe I can at least sell the motors and belts.


Sunday, March 13, 2011

Let the Building Begin!

It's March. Shop time!

Today I started working on the motor/wheel mounting bracket for the foot drive. Unfortunately all I have to show for 3 hours of work is one big problem. I'm having trouble with the scooter wheels I got that are supposed to be compatible with the Razor E100. The axle is 4-1/4" long which is about all the room I have inside the foot shell. This leaves little room above the wheel to build a bracket (the foot shell walls slope in towards the top). Another problem is when the belt is pulled tight the motor is too far on one side to fit in the foot shell.

I'm not sure if I can find a way to make this work. I may need to consider another motor/wheel type. Uuurg. How did others make this work.