Hi Max
I stop the fraying by melting the end directly after cutting with a lighted match, this melts the end fibres together enough to stop them form fraying.


Below is one of the motor mounts for Gabriel finished, all but a little bit of countersinking.
IMG_0869.jpg

As these are American units the tapped holes were 5/16" UNF threads (a little under 8mm) the gearboxes are secured via two bolts at the bottom and two at the top of the gear housing, this leaves the motor overhang on these units, with the thin bolts holding them together, I thought it wise to provide support in the form of a bracket bolted to the motor end plate.

IMG_0868.jpg


The other advantage to this mounting system is the motor units should be easily bolted into any future robot with out too much effort. as the whole assembly can be bolted on to any flat floor-pan with just 4 bolts.