#The Build Post with Updates
Hey everyone! Decided to design a sealed, compact gear drive (2.65 Ratio) of my own to fit 63mm motors while making it compatible with any 184mm caliber trucks commonly available. I'm unsure if this will be for sale in the future, but I've already ordered some of the necessary parts and will making one soon to test it out! Making this thread to be my build and designing log any inputs will be greatly appreciated!
Version 0.1
Version 0.2
Materials forming the gear drive:
Mount: T6 Aluminium
Gear: HP Jet-Fusion Nylon PA12 (May change to CNC-ed POM if Jet Fusion doesn't work)
Pinion: Steel
Wheel Adapter: HP Jet-Fusion Nylon PA12
Mount Cover: HP Jet-Fusion Nylon PA12
Seal: V-Ring Seal
Let me know what ya'll think!
Update (09/09/18):
3rd iteration through 3d printing. Got all the parts to fit nicely. (Ignore the bashed up motor )
Update (10/09/18):
Redesigned it a little to accommodate smaller wheels (97mms) better (chopped off the end by 5mm to give it better ground clearance). Also made the overall footprint of this drive slightly smaller.
With this current gear setup (Module 1.5), I don't think i can get it any smaller to fit 90mm wheels.
Update (11/09/18):
Made it EVEN smaller to hopefully accomodate 90mm wheels now. Internals remain the same. Time to CNC them all!
Update (13/09/18):
Renamed to the Aortal Gear Drive (Name was derived from the blood-red lube i'm going to be using)
Designed a logo to 3d print on to the Cover.
Designed a Kegel-core mount so Kegel wheels shall now fit on this Drive!
Update (26/09/18):
It'll be 2 weeks before my CNCed mounts and motors arrive, can't wait!
In the mean time, my HP Jet-Fusioned parts have arrived and everything fits! Will try to source for a transparent cover (kinda cool to see the internals).
Also updated my design to make space for dual-6355s on the E-Caliber hangar or dual-6374s on the TB218 hangar. Unfortunately, the current design will only accomodate up to a single 63XX on a regular caliber ll mount.
Update (30/09/18):
Fine tuned everything, down to how tight the V-Ring sits. Made a BOM for this gear drive. Eagerly waiting for all the parts to arrive on 8th Oct before I begin assembly and testing. Here's the Aortal Gear Drive in all its glory - This will be the final render and I will be working on a skid plate now.
Update (10/10/2018):
So, the parts are here. Time to get it going. I'm currently in the middle of building a dual belt drive on an aileron deck, so getting another build up to test this will have to wait for abit. I might decide to replace a belt drive on one of my single drive builds to save me some time, we'll see. As always, some pics!
Update (11/10/2018):
Test 1: 15-18kmh @ a 10% gradient.**
Microphone: Huawei P20 Pro
https://www.youtube.com/watch?v=qoZZjb3qyfk&feature=youtu.be
Test 2: 25-30kmh @ a 10% gradient.
Microphone: Huawei P20 Pro
https://youtu.be/_j2FA3eHOU8
Update (17/10/18):
After about 100km on the drive, it's still running really good. I will continue testing this version it breaks or till I hit 1000 km, whichever comes first. Riding about 20 to 30km per day after work to test this out… it's really tiring. (Testing of this drive involves riding at speeds of 20 to 35kmh up and down 10 to 25% inclines to really stress test the drive system).
Few changes to the next version:
- Integrating the Caliber Adapter and Washer together. Also changed chamfer angle to adapt Kegel adapters in the future.
- Increasing width of the Motor Cover Case by 2mm to increase motor shaft clearance (The drive can now work for a max motor shaft length of 30mm).
- Decreasing bearing clearance for an interference fit to the spur gear.
- Increasing size of spur gear mounting holes for a looser fit and better alignment tolerances.
- Exploring the possibility of a CNC-ed POM spur gear.
Update (27/10/2018):
- 250km in and still going strong. Loctite 638 stuff is really insanely strong, I'm surprised at how well it has been holding up.
- Range test has shown an increase in efficiency of about 15 to 20% compared to my previous belt drive. (Tests were conducted using the same board and rider, on the same test route. The amount of energy (Wh) expanded was then recorded to calculate).
- Re-lubed at the 200km mark. V-RING seems to be working really well with very minimal gunk build-up.
- Have managed to source for CNC-ed POM gears as an alternative to 3D printing.
- Made some changes to the 3D printed cover. Increased its width (to achieve a more seamless design) while making it more hollow cheaper to 3d print).
- The motor mount seems to be working flawlessly so far, secured with 4xM8 set screws torqued to 16Nm each, secured with loctite 243.
- Motor mount screws came loose at the 130ish km mark - have since torqued them down to 6Nm and secured them with loctite 243.
- Will now be gauging the interest of these drives for sale. Check the first post for more information.
- The testing continues.
Update (29/10/2018):
- Talked to my suppliers, based on the gauged interest, i’ve decided to order 20 sets, 10 Left and 10 Right sets. (A dual rear drive would require 1 of each set.)
- To keep the cost down, and to have a variety of options, I’ve decided to have it be in a clear finish (shot-peened & clear anodized.) I would then spray paint it to a variety of colours (right now: Candy Red, Candy Blue and Flat Black).
- I’ve made a google order form for those who are interested to get a set or multiple sets. Due to the limited amount of sets i’ll be ordering, I’ll be selling the kits on a first come first served basis. The final price will also be reflected when I issue the payment request through the PayPal emails listed in the google form. I will also update the final price here on the forums.
https://docs.google.com/forms/d/e/1FAIpQLSfgBuTulJXbCGO6cEv7lBuWa77PZ0V3FDgCUdaqh94DBtw1KA/viewform
Note: I'm interested to know if anyone would be interested to purchase these gear drives if I can get the price to around 150USD incl. intl shipping per set (ONE DRIVE) Price should be higher once I’ve figured everything out, it’ll range from 150 to199 USD. (It will include everything in except the motor.) Am thinking of CNCing a batch to lower production costs and sell the rest.
More information to come your way soon, once I have things finalised with my suppliers.