25-Dec-2004

Another day of hard work in the shop... Yes, I know it's xmas and all that, but I just like working. For all those with 'lives' good for you !

So, today I machined the shaft to accept the rear bearing, it's a fairly thin job, at only 30 mm internally, but it's the back of the shaft, so it's mostly a 'thrust' affair on that end.

The front bearing is an 80 od x 50 mm id bearing, very thin race for such a large inner diameter. This is nice because it allows us to reuse the bearing surfaces machined into the housing without modification. We did have to 'open up' the housing a bit to accept the larger shafts, but that does not affect the shoulders the bearing rests on in any way.

We also took a look inside the 'Zubbly' conversion, it's an awesome job done in a thorougly professional way. Something to strive for !

The windings inside Zubbly's 7.5 HP conversion:

The Rotor:

Ok, back to the 10 HP conversion:

Shaft set up ready to turn, the steadyrest is needed because it is so
long, and the center can't be used this close to the end with a bit this large.

The shaft with the bearing pressed on it:

The green tape marks the spot the rotor will have to sink to, the theory is we'll heat up the rotor and drop it on, then it will shrink:

Heating up the rotor:

And that failed miserably... the rotor contracted so fast on contact with the shaft that it shrunk itself fixed after 2"... Shop press to the rescue: (that's a home made one btw)

Rotor in position (about 1/2 hour later... we kept having to release it and put more junk in between. also we lost some hydraulic fluid, the pressure was that high!):

Another view of the shaft with the rotor on it, with a tapemeasure for reference:

Setting up the housing to open up the hole in the end where the shaft passes through:

Last pass on the cut:

50 mm bearing in the hole:

pretty tight fit:

The rotor in the laminations, no magnets or coils yet:

Side by side, the Zubbly conversion (back) and 'ours': (which of course does not work at all yet)