Harm EP1 (Motor Mount)

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Day 1

The first thing I need to do is open up a hole in the chassis to the right because I had to convert from a belt driven differential to a gear. The gear diffs has a larger diameter and that is why I needed to make hole.

Harm EP1

Since I had another chassis to copy from it was very easy for me to make the hole. I placed the chassis on top of each other and traced it.
Harm EP1

Here is the problem after I cut open the hole, the chassis I am using it a bit thinner than the new chassis. So when I mount the differential the gear sticks out past the bottom of the chassis. If the car ever bottoms out the diff gear will rub against the floor. I made these 2 little aluminum spacers to lift the diff up. Harm EP1

Here is the differential mounted on the chassis with the spacers.
Harm EP1

Next up is the intermediate shaft mount. Since I do not have the tools to boar a hole exactly the same size as the bearing on to a flat piece of aluminum, I had to find another way to build in the bearings. I started with a round bar of 7075 aluminum.
Harm EP1

Here you can see the hole I bored out for the bearing.
Harm EP1

To make the intermediate shaft mount as strong as possible I plan to embed this end inside the motor mount. I was able to drill a hole this size on to the motor mount with a hole saw.
Harm EP1

Test fitting the intermediate shaft to make sure the bearings are sitting straight
Harm EP1

 

This is the motor mount that is made of out 1/2 inch thick 6061 aluminum. The next thing I will do is use a hole saw to open a hole of the intermediate shaft mount.
Harm EP1

Here is the intermediate shaft and motor mount being test fitted to the diff.
Harm EP1

 

 

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Day 2

The 1/2 inch motor mount is a bit too think because the motor’s shaft is not long enough to stick out for the pinion to be screwed on.  Here you can see I thinned out the motor mount .
Harm EP1

 

On the other side I milled out a slot so the motor can be adjusted to use different pinion/spur combinations.
Harm EP1

 

Here are a few pictures of the Castle 2200KV motor mounted
Harm EP1

Harm EP1

The next problem I encounter is the differential mount not reaching the upper chassis. I guess the stock EP1 diff mount is different. In this pictures you can see where I plan to cut, which is showing by a red line.
Harm EP1

This is a mock up of the replacement top chassis overlay I will be making.
Harm EP1

Test fitting the top chassis overlay.
Harm EP1

Harm EP1

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