Team Bodge Job

[Ellis]

The motor shaft material might not mind you welding, but of course bear in mind on the other side of the front bearing there is a lot of glue and plastic. Might be worth opening on old motor, seeing what it looks like, close it back up to test weld it, and then seeing if it looks molten or damaged on the inside. If it does, eh...

As for welding the pinion on, if you try to weld the drill shafts they become weak and brittle (something to do with the way they're made) and the gears, as I believe they're made in the same way, may suffer from this too.

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If the motor test weld goes okay, can I suggest you put a small blob of weld on the shaft, then file it down to just a fraction too big for the bore of the gear and try repressing the gear? Essentially the same thing as crimping but you're adding material instead of misshaping it. The shafts are quite tough, you can support the back of the shaft on the other side of the motor and hammer quite hard fairly safely. Just trying to avoid welding the gear as I think it might make it useless.

[plargen]

if i remember correctly with welding the weld itself is strong but there is a patch around it that becomes weak due to the heat, its the bit to do with annealing i think (the rat that steel get cooled cooled affecting their properties)

not 100% but that sortof what i remember from my welding classes 7 years ago

[Bodge Job]

well my welder is actually mig, and i did a lot of testing with the other burn out motor, the insides seemed to turn out fine, i think the brass busing seemed to help act as a heat sink, and the gear seemed to turn out fine and it hasn't weakened a noticeable amount (i tested it thougherly with a hammer) and the weld I did could be ground down enough to fit in the gear box and work.

when i did it on the actual motor and gear it worked fine, just got a small amount of the weld to close to the teeth, so i will have to file that down and sort it out when i have access to my good needle files and dremel. I have tested the motor (out of the gear box) at it all works fine. so im pleased with the results. just will have to test it properly when i have finished.

thanks for the advice though.

[Bodge Job]

Fitted a drill motor with the torque limiter.

http://www.youtube.com/watch?feature...&v=jn4wnMjGVuw



What broke or didn't work:
The gear box was a little loose (internally) as it didn't have the correct number of spacers and the mount caused it to not be able to be tightened completely, so this meant the torque limiter wasn't working completely (it was on the tightest setting on the video)
This looseness meant one of the pins for the gears came out, which jammed the gear box and caused a partial gear chip on the middle gear holder due to uneven load, and the weld broke holding the gear onto the motor as I ground it down to much, will try a different attachment method.

So over all I think is fixable, and means i can change the torque limiter next time so it doesn't loose all its power in the swing, as it felt so much slower than last time, and decreased in speed quiet a bit at the beginning, but im not sure what caused that.
but it was not caused by the battery.

[Bodge Job]

I have fixed it up and sorted it today, i added more spacers into the gearbox, this mean the torque limiter can be set at a higher level.

I have done some testing (with the axe module out of the robot so i can change the limiter easily) I found a good torque amount, but I found that all the screws loosened on the gearbox over time, which meant the torque limiter loosened. Im unsure how to stop this, would lock-tight work on this plastic? for the 4 motor ones I could probably drill them though and bolt them, but would make it hard work and awkward to undo. so probably not a good idea. But do you think lock tight would work?

[Max]

You could mount it like in Tormenta 2 so you support the back of the motor and hold the motor together so those screws no longer do anything.

[Bodge Job]

yes i could probably quiet easily put a plate around the motor to hold it together.
I also did quiet a but of testing and did some worst case scenario stuff as it was running well (like changing direction mid air) ad i did that for a while until the motor burnt out! but i think it will be fine in the end, not as powerful with the clutch, but oh well. and i will stick a permanent cooling fan onto the motor, so it cools down between uses, as the internal fan isn't much use on an axe, so it gets quiet hot, but with that I think it will be fine.