tag:blogger.com,1999:blog-28237419574083787852024-02-20T14:41:09.526-05:00Jaguar's Spot
"If I have seen further than others, it is by standing upon the shoulders of giants" - Isaac NewtonJaguar Kristellerhttp://www.blogger.com/profile/08428337775851273522noreply@blogger.comBlogger32125tag:blogger.com,1999:blog-2823741957408378785.post-10698393482959036272014-04-12T22:47:00.000-04:002014-04-12T22:47:00.539-04:00Tiny Inexpensive Waterjet Freeline SkatesPutz has recently acquired a few <strike>ripsticks</strike> <a href="http://www.razor.com/products/ripstik/" target="_blank">ripstiks</a>. It's probably safe to say that half of the current putzen have mastered how to ride these things. I left my orbit wheels and freeline skates out in the hallway hoping people might want the extra challenge. But, I soon forgot they were on putz, and they were eventually grunged by JoeG's crew. Lately, I've been wanting to orbit wheel; that's enough incentive to build some. I'll probably end up turning this into an Instructable. It would be pretty easy for makers to laser cut, water jet, or possibly 3D print a pair of freeline skates rather than invest $150 in the manufactured version. I tried making them as small as possible to build some intuition for the strength of the aluminum supports.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgf19EJVlB3i3ywlFr4a01sRiXlgpnfHiqFaXV5KCmNeQkJZ26Qry8uRTeNA9vweQFHhhBK5ZGD8XRogLvb8rKivvAgWeyBewS1NNuD8zrNOe4rjYnjia7CjoGKCnFxCbvBj0WxNNRkRV0/s1600/freeline_trucks_CAD.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgf19EJVlB3i3ywlFr4a01sRiXlgpnfHiqFaXV5KCmNeQkJZ26Qry8uRTeNA9vweQFHhhBK5ZGD8XRogLvb8rKivvAgWeyBewS1NNuD8zrNOe4rjYnjia7CjoGKCnFxCbvBj0WxNNRkRV0/s1600/freeline_trucks_CAD.png" height="264" width="320" /></a></div>
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Read after the break for a quick build log:</div>
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I first purchased the smallest/cheapest yellow wheels I could find on <a href="http://www.ebay.com/itm/140932920587?var=440110106604&ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2649" target="_blank">Ebay</a>. I found some perfect 52mm croc yellow wheels and designed the frame around them. </div>
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<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwWvW5jATLY83VWTHmEkvva_AaPLI3AwB1IpA74NxA6g__JFVQjEI5shWB3m8eBA1pLDbBPsmj09T5L9-cxQxXIc8TnyZUKw4oKTmZQZj1_k8gQawid3Ic0dSsX9PVn-QSbCKY0thd-6U/s1600/side_view_CAD.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwWvW5jATLY83VWTHmEkvva_AaPLI3AwB1IpA74NxA6g__JFVQjEI5shWB3m8eBA1pLDbBPsmj09T5L9-cxQxXIc8TnyZUKw4oKTmZQZj1_k8gQawid3Ic0dSsX9PVn-QSbCKY0thd-6U/s1600/side_view_CAD.png" height="198" width="320" /></a></div>
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There really wasn't any other reason for cantilevering the wheels besides making them look "aesthetically pleasing". My main inspiration came from the <a href="https://www.google.com/search?q=freeline+skates&espv=2&biw=1280&bih=896&tbm=isch&imgil=YAChpAjbL67n0M%253A%253Bhttps%253A%252F%252Fencrypted-tbn1.gstatic.com%252Fimages%253Fq%253Dtbn%253AANd9GcTnTDKA3SxmK_MLC8fvb8u915HEIZ50YkM9lGgwwwACk6rtOy_8HA%253B800%253B533%253BinOKHdo3edyihM%253Bhttp%25253A%25252F%25252Fen.wikipedia.org%25252Fwiki%25252FFreeline_skates&source=iu&usg=__dB8knmb5bJf5efmLhIhZevauEO8%3D&sa=X&ei=Je9JU7QLqLawBJHEgLAN&ved=0CEQQ9QEwAw#facrc=_&imgdii=_&imgrc=YAChpAjbL67n0M%253A%3BinOKHdo3edyihM%3Bhttp%253A%252F%252Fupload.wikimedia.org%252Fwikipedia%252Fcommons%252Ff%252Ff1%252FFreelines2.jpg%3Bhttp%253A%252F%252Fen.wikipedia.org%252Fwiki%252FFreeline_skates%3B800%3B533" target="_blank">expensive manufactured freeline</a> skate designs, and the fact that the double supported design didn't look as cool. I was also curious to see how the material would hold up. I tend to over engineer most things. </div>
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It was relatively simple to CAD up quickly. Thankfully, I still have access to CSAIL's waterjet.<br />
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After cutting them out, I drilled and tapped the holes, and assembled them with 6-32 socket cap screws. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdtC6RM8WYZzCGBXvLUK1Bk0ptuYxZEz5Nm_TDPygy3AmCZeUQ-9FR6zqLeUmcFW3sKSqucBcmuSAi5RWulIG3s36etnxSJ7XJIMFa68288gIiKp0irAueY14vW-uWLpqgcJfjdb4Wjqs/s1600/2014-03-29+01.35.28.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdtC6RM8WYZzCGBXvLUK1Bk0ptuYxZEz5Nm_TDPygy3AmCZeUQ-9FR6zqLeUmcFW3sKSqucBcmuSAi5RWulIG3s36etnxSJ7XJIMFa68288gIiKp0irAueY14vW-uWLpqgcJfjdb4Wjqs/s1600/2014-03-29+01.35.28.jpg" height="239" width="320" /></a></div>
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Because the wheels are cantilevered, they aren't perfectly parallel (making riding a bit trickier). After extensive use, the supports have bent a little but not as significantly as I'd imagined. This design was mostly a quick prototype to get some orbit wheels on putz quickly. I'd like to use the MITERS CNC to make a more durable shiny pair. </div>
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<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgM0A97GvyXPSjeDXaWjgMwauaZnDy743oL15h0UxRaA1k6P2WggteAzfnmgJ9KpHwCBC3uqPwqEwgy5VcD2ciY3lQfXbBOtjEoR537BTFykR_gcKpilHvzFcIM2KoE-wDg6Yg1-FqBS7E/s1600/tinyline_skates.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgM0A97GvyXPSjeDXaWjgMwauaZnDy743oL15h0UxRaA1k6P2WggteAzfnmgJ9KpHwCBC3uqPwqEwgy5VcD2ciY3lQfXbBOtjEoR537BTFykR_gcKpilHvzFcIM2KoE-wDg6Yg1-FqBS7E/s1600/tinyline_skates.jpg" height="252" width="320" /></a></div>
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Jaguar Kristellerhttp://www.blogger.com/profile/08428337775851273522noreply@blogger.com7tag:blogger.com,1999:blog-2823741957408378785.post-25885795563899368702014-02-24T02:43:00.003-05:002014-04-12T22:49:15.663-04:00Bot Blast July 2013I've been falling into this trend of posting weeks or even a months after the fact (actually it's not even a trend anymore; I just haven't been posting). This will hopefully stop as soon as I've settled on one website with a stable blogging system. (I currently have <a href="http://jaguark.mit.edu/">jaguark.mit.edu</a>, where I'm playing around with Drupal, <a href="http://jaguark.wordpress.com/">jaguark.wordpress.com</a>, <a href="http://kriste11er.com/">kriste11er.com</a>, and this site). I have to say, I probably wouldn't have gotten around to posting this if it weren't for my awesome cousin Alex, who was fascinated by the mini battle bots.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNzvAcqEYd4CR1K8Ndl4D0m0lYrAkVOcmWpm-PTcmvEIPxd1HkVm0mvJCPR7BtXtDwKScc5NvWpK3neRbQma38Kz7INSIWE_FgCk6Iq3OjT5brgoH56p1GOrgZjejVn_HmtE_oukQsvxc/s1600/2013-07-20+10.52.13.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgNzvAcqEYd4CR1K8Ndl4D0m0lYrAkVOcmWpm-PTcmvEIPxd1HkVm0mvJCPR7BtXtDwKScc5NvWpK3neRbQma38Kz7INSIWE_FgCk6Iq3OjT5brgoH56p1GOrgZjejVn_HmtE_oukQsvxc/s320/2013-07-20+10.52.13.jpg" height="478" width="640" /></a></div>
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So. How I unexpectedly built a mini battle bot over night:<br />
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I had just finished fixing up the <a href="http://kriste11er.blogspot.com/2013/10/repairing-42-plasma-lg-tv.html" target="_blank">42" TV</a> I had recently crufted, and went over to MITERS. <a href="http://transistor-man.com/" target="_blank">Dane</a> and <a href="http://build-its.blogspot.com/" target="_blank">Ben</a> were working on their last minute robots. <a href="http://etotheipiplusone.net/" target="_blank">Charles</a> had extra motors, battery packs, and a seat in mikuvan. And why not?<br />
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I started with a previous ant weight battle bot frame that Charles had laying around.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhlICqxBZXjrEVvHnTvc38phakPhgOndncM8y_gtGGzEGZ6a-CSvi-HfiESVEtbD08XyAP3lqBnEayOBEyZDG_3Ye0qMNOpHOOjMDS-D8zd_6XzM1hJob7Ew-8XBMTzYIVMicTRDqbE5jg/s1600/2013-07-19+02.44.55.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhlICqxBZXjrEVvHnTvc38phakPhgOndncM8y_gtGGzEGZ6a-CSvi-HfiESVEtbD08XyAP3lqBnEayOBEyZDG_3Ye0qMNOpHOOjMDS-D8zd_6XzM1hJob7Ew-8XBMTzYIVMicTRDqbE5jg/s320/2013-07-19+02.44.55.jpg" height="478" width="640" /></a></div>
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I found a piece of round steel stock that the motors fit in perfectly. It helped make the bot heavier in its center. I milled out the middle section to allow for the motor wires to exit.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDDbC7wAEzzSM0sFPpJkx7VdrpoqvcicC3uA7seE-QbKoVr3fvQ_RyQG450B-Q80v-tHfprfANFwzYwReunHpiBGybVwLQ22xysWgpgMxY0bZWSbXR0Q15NXkeSYv1aHdM_kn0eDoS-TU/s1600/2013-07-19+03.58.00.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDDbC7wAEzzSM0sFPpJkx7VdrpoqvcicC3uA7seE-QbKoVr3fvQ_RyQG450B-Q80v-tHfprfANFwzYwReunHpiBGybVwLQ22xysWgpgMxY0bZWSbXR0Q15NXkeSYv1aHdM_kn0eDoS-TU/s320/2013-07-19+03.58.00.jpg" height="478" width="640" /></a></div>
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As for the wheels, I turned them on the <a href="http://miters.mit.edu/" target="_blank">MITERS</a> lathe and used o-rings for the tires.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivyHZqbRTFKl2l32-tE0wvSIaXgG9QQDhOA-7WBd9RVsv5vpY_RW7fM7qjRgFV0VY2rX4VW9fwZHWusI40_Zge5p8NP9uzONBF5Mjy44PokbtWEL16OSzm6QuRwguUotk1c7SD3y1VeNo/s1600/2013-07-19+12.14.10.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivyHZqbRTFKl2l32-tE0wvSIaXgG9QQDhOA-7WBd9RVsv5vpY_RW7fM7qjRgFV0VY2rX4VW9fwZHWusI40_Zge5p8NP9uzONBF5Mjy44PokbtWEL16OSzm6QuRwguUotk1c7SD3y1VeNo/s320/2013-07-19+12.14.10.jpg" height="478" width="640" /></a></div>
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I ran over to the MIT COOP to get a notebook with a good flexible plastic cover to use as the ramp. It worked surprisingly well; nothing could get underneath, because it slid along the floor (unlike the metal ramps that are about a millimeter off the ground).<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqznqK9WfGsSxYkqlXMT-p9cNAAKbE78ev6AeeuzS4FDPF8MJDR2E7TZzqMHUJAwtrXHMEzn8GZiBUnZeofgPeD9lN41oiJWpSjluFAnIq0_4yCnnsxxkurlOGsYPvrfZ5CYe4s-dVyQA/s1600/2013-07-20+09.54.16.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqznqK9WfGsSxYkqlXMT-p9cNAAKbE78ev6AeeuzS4FDPF8MJDR2E7TZzqMHUJAwtrXHMEzn8GZiBUnZeofgPeD9lN41oiJWpSjluFAnIq0_4yCnnsxxkurlOGsYPvrfZ5CYe4s-dVyQA/s320/2013-07-20+09.54.16.jpg" height="478" width="640" /></a></div>
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In the last hour before we left for Pennsylvania, <a href="http://build-its-inprogress.blogspot.com/" target="_blank">Ben</a> helped me solder up the electronics. It drove minutes before getting packaged up for the long drive.<br />
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One the ride down, we brainstormed possible names for the last minute ant weight. To name just a few: The-Dead-Hooker-Under-A-Rug, Hooker-Under-A-Rock (suggested by <a href="http://wattsdottime.blogspot.com/" target="_blank">Jullian</a>), and Speed Bump. </div>
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<b>Bot Blast 2013 Competition:</b></h3>
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My relatives live 40 minutes from the competition, so I invited them to come out and watch. My uncle Ted, and cousins Alyssa and Alex made it out to watch, and can be seen in the stands of some of the videos. </div>
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My first match was against <a href="http://thevariableconstant.blogspot.com/" target="_blank">Jameson's</a> <a href="http://thevariableconstant.blogspot.com/2013/07/cake-slice-and-pa-bot-blast-2013.html" target="_blank">DDT</a>, an impressive bot with a high speed horizontal steel saw. The notebook cover did pretty well against the saw. I thought it would get torn to shreds, but it was able to scoop underneath and protect itself (there was no way I'd win this match; even if it were a tie the judges would rule DDT more aggressive). My only hope was to not get severely damaged, please the crowd by deflecting DDT to fly around and make loud noises, and to have fun. </div>
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Unfortunately, Jameson was able to get a solid connection with the side aluminum wheel support, causing the axle to pinch and leaving Speed Bump immobilized. I tapped out before getting further damaged.</div>
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My second match was also against Jameson with his 3D-printed Cake Slice. This was a fairly even match; two wedges battling it out. Cake Slice got stuck near the end. I probably could have won the match by leaving him stuck, but I tried to be a good-sport and freed him. The judges ended up ruling Cake Slice the victor. </div>
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The tournament was double elimination, so that was the end of my first battle bot competition.</div>
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During a break, Ben practiced trying to fling Speed Bump with his <a href="http://build-its-inprogress.blogspot.com/2013/07/bot-blast-recap.html" target="_blank">Glorified Door Stop</a> like he had done the night before in MITERS. </div>
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Credit for the videos goes to <a href="http://wattsdottime.blogspot.com/" target="_blank">Jullian</a> and <a href="http://etotheipiplusone.net/" target="_blank">Charles</a>.<br />
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Jaguar Kristellerhttp://www.blogger.com/profile/08428337775851273522noreply@blogger.com1tag:blogger.com,1999:blog-2823741957408378785.post-10502529512607312862013-12-11T06:07:00.001-05:002013-12-11T16:25:59.970-05:00VDSKart: TIG Welding Aluminum FrameI've been meaning to build an electric vehicle a bit more exciting than my <a href="http://kriste11er.blogspot.com/p/completed_21.html#electric_orbit_wheel" target="_blank">Electric Orbit Wheels</a>. And by a bit more exciting, I mean <a href="http://build-its-inprogress.blogspot.com/search/label/ATS%20Redux" target="_blank">ridiculous acceleration</a>, <a href="http://scolton.blogspot.com/p/cap-kart.html#tinykart" target="_blank">drifting</a>, and <a href="http://www.youtube.com/watch?v=jySouCYX8ss" target="_blank">driving around MIT campus</a> at odd hours of the night. It's about time I built something that I could bring along and race <a href="http://build-its.blogspot.com/2013/03/electric-tricycle.html" target="_blank">Ben's trike</a> in the <a href="http://www.youtube.com/watch?v=NsUHxKSFBcA" target="_blank">Stata basement</a>. I've accumulated a few very nice parts from the recently deceased club in N51, Vehicle Design Summit (VDS). Most of this kart will be assembled from parts I scrounged from VDS: hence the name VDSKart.<br />
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Due to the ridiculous size of the solar car axial flux motor that Ben generously donated, this vehicle is going to be a full sized racing go-kart, a slight deviation from MITER's smaller electric vehicles. It's probably going to weigh upwards of 150 lbs and won't fit through doorways, but it will go really really fast and accelerate like a sports car. I'm using aluminum round tubing for the frame to decrease weight, to learn how to weld aluminum, and because it's available.<br />
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After looking at many different designs for racing go-karts, I came up with this frame.<br />
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More on practice welds and crufted parts after the break. </div>
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Mars had the rear-axle of a racing go-kart laying near his shelf. It's about 3'6" wide (small enough to fit through Stata elevators), 1.25" in diameter, has a keyway cut along its entire length, includes spherical bearing hubs, and has clamp hubs for both the brake disc and drive sprocket. </div>
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As for welding, I talked with Jack Whipple and he kindly taught me how to TIG weld in his shop, D-Lab. </div>
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Before tackling the whole frame, I welded some small aluminum scraps together in order to get a feel for TIGing aluminum. From my short experience, I've noticed it's very different from welding steel. There's more cleaning involved due to the oxidation layer aluminum makes almost instantly, and aluminum doesn't cool as rapidly as steel does. Steel is also much more forgiving. It doesn't take much to melt through the aluminum piece. </div>
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After welding, I broke it to test my welds.<br />
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I bent the plate quite a bit, but it just tore along the welds. This indicates that I didn't melt enough of the base material and added to much filament.<br />
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Excited after welding, I went and CADed a rough frame in SolidWorks.<br />
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I soon learned that the joints containing four different aluminum pipes would be extremely hard to weld with my current welding ability. </div>
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Next I tried TIGing a mitered edge to a pipe.<br />
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Welding the inside of the right angled miter joint was very difficult. I definitely don't want to weld joints with more than two pieces intersecting. I do want the challenge of welding my own frame, but I don't want building the frame to take up most of my time on this project. After welding the mitered edge at a right angle, I went and changed my initial frame design significantly to reduce any joints to two members and most angled joints to right angles. In this case, practicing welding a few scraps together helped constrain the design.<br />
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It took a bit more force with the wrench to break the weld. However, it still broke at the weld. I'll need a bit more practice getting the balance between using the existing material and not burning through it.<br />
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For safety considerations and to make welding the joints a bit easier, I pondered buying <a href="http://www.mscdirect.com/browse/Hose-Tube-Fittings-Valves/Fittings-Couplings/Plumbing-Pipe-Fittings/Pipe-Fittings/Aluminum-Pipe-Fittings?navid=12105031+4287978914" target="_blank">aluminum pipe fittings</a>. That way, I could just weld a two-dimensional circle rather than a three-dimensional mitered edge path. However, they're cost is almost an order of magnitude more expensive than <a href="http://www.homedepot.com/b/Plumbing-Pipes-Fittings-Valves-Copper-Pipe-Fittings/Elbow/N-5yc1vZbuu2Z1z114xe" target="_blank">copper fittings</a>.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg0z0-7ePUFBeMge31NUc6zaurD5Gby8xgDfdYHx63BRtsBWHY0DX4c19pnx-lRbaxFVN56pbbZgPaTa4rE_U_kOztl9JRJybwvSfQgGlSDzcYoooRqUOYDEBrVwS0QIqaA0oVadDjWB_U/s1600/243.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg0z0-7ePUFBeMge31NUc6zaurD5Gby8xgDfdYHx63BRtsBWHY0DX4c19pnx-lRbaxFVN56pbbZgPaTa4rE_U_kOztl9JRJybwvSfQgGlSDzcYoooRqUOYDEBrVwS0QIqaA0oVadDjWB_U/s640/243.JPG" width="640" /></a></div>
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Just as I was getting the hang of TIG welding aluminum, I <strike>borked my collarbone</strike> fractured my left clavicle <strike>skating really fast into walls</strike> playing hockey. This delays everything, including welding the frame. On the pain medication it says, "Do not operate <strike>lathes, mills, bandsaws...</strike> heavy machinery." I guess that is actually relevant now.</div>
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Here's a cool X-ray of my broken body. I'm going to have to get surgery so they can implant a titanium plate. Step one of becoming a robot... check. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbV_bFlgSHbHTZmS3iEmUfVfC86-iacveneI47AgrQ1uOZZ1aaQ7bIDisdZ7S0qVBvXYK-J913XtSmbgvKPEGhLMeaSEbhMnQLu_9P_7qNPyk1UU-JReB20-v9xF2EQWMzh2Ob7eFwY48/s1600/left_collarbone.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="314" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbV_bFlgSHbHTZmS3iEmUfVfC86-iacveneI47AgrQ1uOZZ1aaQ7bIDisdZ7S0qVBvXYK-J913XtSmbgvKPEGhLMeaSEbhMnQLu_9P_7qNPyk1UU-JReB20-v9xF2EQWMzh2Ob7eFwY48/s640/left_collarbone.png" width="640" /></a></div>
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Though I might not be able to machine or weld things at MITERS with a borked bone, I can still CAD. Here's a somewhat pretty finished frame with the added design constraints.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwJCRAJk1WuqrBpmp5S9PS9Jp8aYFrlJS1ea50Z9i4FNvSAVlroV_bTzzZEWZ8G6aUv3gs9X2fYJjo20COrERyTRxBERcGOlAnC3KZRyu7g1oFt1vjYNVFWsxTTBlG6MSGquNPhjnbCKk/s1600/frame_weld5.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="258" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhwJCRAJk1WuqrBpmp5S9PS9Jp8aYFrlJS1ea50Z9i4FNvSAVlroV_bTzzZEWZ8G6aUv3gs9X2fYJjo20COrERyTRxBERcGOlAnC3KZRyu7g1oFt1vjYNVFWsxTTBlG6MSGquNPhjnbCKk/s640/frame_weld5.png" width="640" /></a></div>
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More to come on machining a mount for the pancake motor and welding the frame. </div>
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Jaguar Kristellerhttp://www.blogger.com/profile/08428337775851273522noreply@blogger.com9tag:blogger.com,1999:blog-2823741957408378785.post-74824616623796244092013-11-04T18:00:00.003-05:002013-11-18T18:03:35.996-05:00Shortest Path to MITERS<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqsI0uh3br_WceKqhKp9-N-Q9XiMte2sMUxdzkNxOjdM0S2CPE8yZJ_4G1EZyznJ_oHQVJBin-FM_OmTlxO5gQBf02pPPGWsmbZEmuvOch4W3w1AYm_Tr1asZd9dIrnBgIYZccWorOGis/s1600/miters_route.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="396" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqsI0uh3br_WceKqhKp9-N-Q9XiMte2sMUxdzkNxOjdM0S2CPE8yZJ_4G1EZyznJ_oHQVJBin-FM_OmTlxO5gQBf02pPPGWsmbZEmuvOch4W3w1AYm_Tr1asZd9dIrnBgIYZccWorOGis/s640/miters_route.jpg" width="640" /></a></div>
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I finally got around to precisely measuring the different EC to MITERS routes on Google Earth. I wasn't sure how the path through the Swapfest parking lot compared to the others, but this confirms its about the same distance. As for the numbers:</div>
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White = 693 meters (the absolute shortest distance to MITERS from EC)</div>
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Red w/shortcut = 848 m (includes the sidewalk currently blocked by construction on building 35)</div>
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Red w/o shortcut = 856 m</div>
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Blue = 858 m</div>
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Purple = 858 m</div>
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Orange = 964 m</div>
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So really, the shortest path is past Building 13 and along Mass Ave with the diagonal sidewalk towards the intersection of Mass Ave. and Vassar (which only saves 10 meters (+/- measurement error)). </div>
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The red path is also probably the fastest because of the straight stretch past Building 13. However, I've gotten a little bored of the same route, and have now switched to the purple path (even though it's 2-10 meters longer). </div>
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Just for kicks, here's the same route placed over MIT the year after I was born.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLt6NBdI2P88NIC3P00ooCI9HJK-BxysCRmWduZxwNXVuXE86CbqGk38S7fD1-HyCODvEoGysWmGHNB-xLmY4PPHwiUnXjmmjNilkx58cXhgaBwh-KFepK5mPS_S3aBcf9tmyH9_8kZ7U/s1600/miters_route_1995.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="396" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLt6NBdI2P88NIC3P00ooCI9HJK-BxysCRmWduZxwNXVuXE86CbqGk38S7fD1-HyCODvEoGysWmGHNB-xLmY4PPHwiUnXjmmjNilkx58cXhgaBwh-KFepK5mPS_S3aBcf9tmyH9_8kZ7U/s640/miters_route_1995.jpg" width="640" /></a></div>
<br />Jaguar Kristellerhttp://www.blogger.com/profile/08428337775851273522noreply@blogger.com1tag:blogger.com,1999:blog-2823741957408378785.post-57286700989040490682013-10-05T22:39:00.001-04:002013-10-06T21:35:23.463-04:00Earth in the Foreground: Building the Pan/Tilt Time-lapse Platform<div class="separator" style="clear: both; text-align: center;">
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjjf5x5SVP1kyD3Z3G_M8x8nHd8fXOOdeAl2W_QaeFBS1XWkET8cHabZDHeF6dOPDKMtK81BtkJzvlx0HMXZiHbDjeuZCKV-xrDDhmL5JpUwDhKBZfhLb4ofOmPueEeDQ9RTqnSGzhlzk/s1600/2013-06-19+01.05.43.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhjjf5x5SVP1kyD3Z3G_M8x8nHd8fXOOdeAl2W_QaeFBS1XWkET8cHabZDHeF6dOPDKMtK81BtkJzvlx0HMXZiHbDjeuZCKV-xrDDhmL5JpUwDhKBZfhLb4ofOmPueEeDQ9RTqnSGzhlzk/s640/2013-06-19+01.05.43.jpg" width="640" /></a></div>
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Before <a href="http://www.kriste11er.blogspot.com/2013/06/earth-in-foreground-flying-into.html" target="_blank">heading up to Alaska</a> to film the Sun up above the Arctic Circle, I made a device to slowly move the camera in pitch and yaw using some of Joseph's stepper motors and scrap metal around CSAIL. </div>
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First press fit... ever.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-WqDaKePnffCOvtsCBDL0YyhnNn8pssthCkkOyDJRiR0CH4yGWDsU-aAw6KpSxwsj6ZVlQ0QTUHIKQK8FtsNSJsdUFn3uGvsUMGFKYYzejk3AruNon7cIgzguwBgxGyvyuBCklf9HjAU/s1600/2013-06-17+17.54.06.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-WqDaKePnffCOvtsCBDL0YyhnNn8pssthCkkOyDJRiR0CH4yGWDsU-aAw6KpSxwsj6ZVlQ0QTUHIKQK8FtsNSJsdUFn3uGvsUMGFKYYzejk3AruNon7cIgzguwBgxGyvyuBCklf9HjAU/s640/2013-06-17+17.54.06.jpg" width="640" /></a></div>
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Because I didn't have an abundant amount of scrap rectangular stock, I used a scrap piece of metal to test the hole size to get the press fit right.</div>
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<a href="http://3.bp.blogspot.com/-mFRHtIqmqP8/UcwFRxFzjnI/AAAAAAAABj4/x6Faf3X78Fs/s1600/2013-06-17+18.08.30.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://3.bp.blogspot.com/-mFRHtIqmqP8/UcwFRxFzjnI/AAAAAAAABj4/x6Faf3X78Fs/s640/2013-06-17+18.08.30.jpg" width="640" /></a></div>
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To press the bearing in the rectangular stock, I used another smaller square tube as support. Otherwise, the force from the vice would just crush the piece. </div>
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<a href="http://1.bp.blogspot.com/-iQfRS1-Zx9k/UcwFjYPK3CI/AAAAAAAABkw/pkURFnh3VOc/s1600/2013-06-18+00.28.18.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-iQfRS1-Zx9k/UcwFjYPK3CI/AAAAAAAABkw/pkURFnh3VOc/s640/2013-06-18+00.28.18.jpg" width="640" /></a></div>
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I found a ridiculously large thrust bearing in MITER's drawer of "Big Bearings". It could probably support loads upwards of hundreds of pounds, but I thought it would be pretty funny to use on a small camera gantry. </div>
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<a href="http://2.bp.blogspot.com/-up7o0LEHZIE/UcwFghiTwSI/AAAAAAAABko/hlcpgios_uE/s1600/2013-06-18+00.18.10.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://2.bp.blogspot.com/-up7o0LEHZIE/UcwFghiTwSI/AAAAAAAABko/hlcpgios_uE/s640/2013-06-18+00.18.10.jpg" width="640" /></a></div>
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So I turned a coupling for the thrust bearing to press fit onto the radial bearing.<br />
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It was a bit too large to press fit into the thrust bearing, but once I started I couldn't really stop. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6SxDwROSbML_Wrll5xy4Mbit4BaW1ttyoQTgN1tXDD3ANr4H00Z6Q4AFssyJl8RztcK6gRgycKQf5BzRQ6UzVYFWPihyphenhyphenyfRDV94PBuK6Ngsud_XRFtpwXtHDHDSKsoplPTvY-blmeVt0/s1600/2013-06-18+00.44.10.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6SxDwROSbML_Wrll5xy4Mbit4BaW1ttyoQTgN1tXDD3ANr4H00Z6Q4AFssyJl8RztcK6gRgycKQf5BzRQ6UzVYFWPihyphenhyphenyfRDV94PBuK6Ngsud_XRFtpwXtHDHDSKsoplPTvY-blmeVt0/s640/2013-06-18+00.44.10.jpg" width="640" /></a></div>
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The radial bearing press fitted into the body, the aluminum coupling press fitted onto the radial bearing, the thrust bearing press fitted onto the aluminum coupling... So many press fits!</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXik5WkwNd3iHkE7iRefGbQE28Ed7VzVhKebszhUf2i3Y5ZWF3lOsxyRuple8Uc9MsTVIwmbiSoW5PAPuVphBVIzgXOyOk8pbnG2Iy7hk7JvWVt3NshD97iaQdf6ukMUD5y0znnUq6Zfk/s1600/2013-06-18+05.22.02.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhXik5WkwNd3iHkE7iRefGbQE28Ed7VzVhKebszhUf2i3Y5ZWF3lOsxyRuple8Uc9MsTVIwmbiSoW5PAPuVphBVIzgXOyOk8pbnG2Iy7hk7JvWVt3NshD97iaQdf6ukMUD5y0znnUq6Zfk/s640/2013-06-18+05.22.02.jpg" width="640" /></a></div>
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<a href="http://4.bp.blogspot.com/-OOPQeBCMGFI/UcwF1apgMBI/AAAAAAAABl4/jsF-5QZJCAc/s1600/2013-06-18+06.33.16.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://4.bp.blogspot.com/-OOPQeBCMGFI/UcwF1apgMBI/AAAAAAAABl4/jsF-5QZJCAc/s640/2013-06-18+06.33.16.jpg" width="640" /></a></div>
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And to add yet another press fit, I turned a large piece of aluminum on the lathe to make a base for the other half of the ridiculously large thrust bearing. The pan/yaw axle also press fits into the base, so the gantry can rotate about it.<br />
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Ideally, the camera lens would lie on the axis of pitch rotation. I wasn't pleased with the designs I had sketched for this orientation. The two main factors that pushed me over to an offset axis design were: the sun is so far away that the distance between my axis of rotation and the lens is negligible, and not all camera's are the same. <br />
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<a href="http://2.bp.blogspot.com/-3gQ-QMgjp-M/UcwF6IJDlGI/AAAAAAAABmI/GhixawE5KK4/s1600/2013-06-18+07.39.42.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://2.bp.blogspot.com/-3gQ-QMgjp-M/UcwF6IJDlGI/AAAAAAAABmI/GhixawE5KK4/s640/2013-06-18+07.39.42.jpg" width="640" /></a></div>
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I designed some side supports in SolidWorks and cut them out on the water jet. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGW6B_ed4pA0jDkKFwfydGU_XhqQA1h-t7j_YmRN3Lhff2aAHsKZJmuj4_t2Ykes0-rAQqROuYYkTzTBO0LLGDxb9gOqrxJTgPnU1n3pTQA_6IDXanQCFxR39cGWpy3Kbwh5qeUUZZZJE/s1600/2013-06-18+07.26.18.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGW6B_ed4pA0jDkKFwfydGU_XhqQA1h-t7j_YmRN3Lhff2aAHsKZJmuj4_t2Ykes0-rAQqROuYYkTzTBO0LLGDxb9gOqrxJTgPnU1n3pTQA_6IDXanQCFxR39cGWpy3Kbwh5qeUUZZZJE/s640/2013-06-18+07.26.18.jpg" width="640" /></a></div>
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That was probably the fastest part I've ever water jetted. </div>
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<a href="http://2.bp.blogspot.com/-UfhGOaaGHFk/UcwF6_c-MTI/AAAAAAAABmQ/lwzpD21iGoY/s1600/2013-06-18+09.12.47.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://2.bp.blogspot.com/-UfhGOaaGHFk/UcwF6_c-MTI/AAAAAAAABmQ/lwzpD21iGoY/s640/2013-06-18+09.12.47.jpg" width="640" /></a></div>
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<a href="http://1.bp.blogspot.com/-fwZ-ksd-5rI/UcwGH413zWI/AAAAAAAABnA/HJdGjLVVdbk/s1600/2013-06-18+11.03.47.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-fwZ-ksd-5rI/UcwGH413zWI/AAAAAAAABnA/HJdGjLVVdbk/s640/2013-06-18+11.03.47.jpg" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbOSrlcsqLJ7Nr6cFI4sRvwZDj5oIR85AZUl-yaDsoIgxRFPGyzHL6tmZJOG6dE-qXEqm7jffNIJumeRIUAFHQxxbb7cFslKg9zTaRo1SQmaXllG31b6f14ozFyVUMrySyQ2y8SbWQ7rA/s1600/2013-06-18+10.38.12.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbOSrlcsqLJ7Nr6cFI4sRvwZDj5oIR85AZUl-yaDsoIgxRFPGyzHL6tmZJOG6dE-qXEqm7jffNIJumeRIUAFHQxxbb7cFslKg9zTaRo1SQmaXllG31b6f14ozFyVUMrySyQ2y8SbWQ7rA/s640/2013-06-18+10.38.12.jpg" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2OP_HHyorKohgCcduCvFaLnqjU9O090garTJ45nfy5F-BQqwxUDkKi9kmqEQUTUudMQMAhBCHyRbjuP7qXzv37dYljV52GB9EkStOrtT8IFQHTO2gLLFBL8gDikE_DiwHgYPVYumezvc/s1600/2013-06-18+10.40.04.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2OP_HHyorKohgCcduCvFaLnqjU9O090garTJ45nfy5F-BQqwxUDkKi9kmqEQUTUudMQMAhBCHyRbjuP7qXzv37dYljV52GB9EkStOrtT8IFQHTO2gLLFBL8gDikE_DiwHgYPVYumezvc/s640/2013-06-18+10.40.04.jpg" width="640" /></a></div>
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I wasn't sure how well the bearings would press fit into a water jetted part, so I designed it with smaller holes and expanded them after water jetting. I chose to put the bearing facing outward to give more room for the camera inside and act as a spacer for the gear.<br />
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<a href="http://4.bp.blogspot.com/-2qnZlhfNccU/UcwF6wjpicI/AAAAAAAABmU/gzAgpMiZEhc/s1600/2013-06-18+08.21.13.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://4.bp.blogspot.com/-2qnZlhfNccU/UcwF6wjpicI/AAAAAAAABmU/gzAgpMiZEhc/s640/2013-06-18+08.21.13.jpg" width="640" /></a></div>
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<a href="http://3.bp.blogspot.com/-xdAC2eicjKo/UcwGBLiKOpI/AAAAAAAABmk/JLOQXYdqtc0/s1600/2013-06-18+09.50.31.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://3.bp.blogspot.com/-xdAC2eicjKo/UcwGBLiKOpI/AAAAAAAABmk/JLOQXYdqtc0/s640/2013-06-18+09.50.31.jpg" width="640" /></a></div>
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Drilled holes for the stepper motors.</div>
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<a href="http://1.bp.blogspot.com/-1_LAmSYFcsc/UcwGGwgsyTI/AAAAAAAABm4/VchjJ_L17VE/s1600/2013-06-18+10.53.21.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-1_LAmSYFcsc/UcwGGwgsyTI/AAAAAAAABm4/VchjJ_L17VE/s640/2013-06-18+10.53.21.jpg" width="640" /></a></div>
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I used some of CSAIL's tiny 4-40 screws to hold it all together. </div>
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<a href="http://1.bp.blogspot.com/-V-nYiLJ3MiM/UcwGIWIaRlI/AAAAAAAABnI/hLbETEolbwc/s1600/2013-06-18+11.13.09.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-V-nYiLJ3MiM/UcwGIWIaRlI/AAAAAAAABnI/hLbETEolbwc/s640/2013-06-18+11.13.09.jpg" width="640" /></a></div>
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I consolidated space with the stepper motors so I could put the motor controllers on the other half. </div>
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<a href="http://4.bp.blogspot.com/-R5IvMv7dCdQ/UcwGMA6pyoI/AAAAAAAABnQ/8EmUW-O5FeA/s1600/2013-06-18+11.44.12.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://4.bp.blogspot.com/-R5IvMv7dCdQ/UcwGMA6pyoI/AAAAAAAABnQ/8EmUW-O5FeA/s640/2013-06-18+11.44.12.jpg" width="640" /></a></div>
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To be able to see the motor controller indicator LEDs, I milled a diagonal on the base. </div>
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<a href="http://2.bp.blogspot.com/-QHw-DG0k8XQ/UcwGRPLa_-I/AAAAAAAABnk/ftezSBej538/s1600/2013-06-18+11.55.12.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://2.bp.blogspot.com/-QHw-DG0k8XQ/UcwGRPLa_-I/AAAAAAAABnk/ftezSBej538/s640/2013-06-18+11.55.12.jpg" width="640" /></a></div>
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<a href="http://1.bp.blogspot.com/-fxQjDPKabLw/UcwGQ1lBDnI/AAAAAAAABnc/II_OEK8REnU/s1600/2013-06-18+12.56.20.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-fxQjDPKabLw/UcwGQ1lBDnI/AAAAAAAABnc/II_OEK8REnU/s640/2013-06-18+12.56.20.jpg" width="640" /></a></div>
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I ended up opening up the bottom hole so the pan/yaw stepper motor axle could slide in. </div>
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<a href="http://1.bp.blogspot.com/-ncIoBZSIyiI/UcwGab5jGfI/AAAAAAAABn4/qUGkySNUWuI/s1600/2013-06-18+17.13.15.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-ncIoBZSIyiI/UcwGab5jGfI/AAAAAAAABn4/qUGkySNUWuI/s640/2013-06-18+17.13.15.jpg" width="640" /></a></div>
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To make the axle that the camera rests on, I turned down a piece of square stock with a four-jaw-chuck to make both ends a quarter inch in diameter. </div>
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<a href="http://3.bp.blogspot.com/-Q8K9QyTDpPU/UcwGbSf90TI/AAAAAAAABoA/QgqXtgFvD9o/s1600/2013-06-18+18.21.18.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://3.bp.blogspot.com/-Q8K9QyTDpPU/UcwGbSf90TI/AAAAAAAABoA/QgqXtgFvD9o/s640/2013-06-18+18.21.18.jpg" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEZ704gjqKZZgqMc_dwZPSYgzrSOl3Ug3ixSKessjKxG9qNh75HtK9pqb4IgRAhzWfUVp28W75VQJFfkmqB68U9x7G7rBL8EAWlotTKYxtxzVXwJfBAlldJiBXRBAjlDsphAeo8PvcCSU/s1600/2013-06-18+18.20.52.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEZ704gjqKZZgqMc_dwZPSYgzrSOl3Ug3ixSKessjKxG9qNh75HtK9pqb4IgRAhzWfUVp28W75VQJFfkmqB68U9x7G7rBL8EAWlotTKYxtxzVXwJfBAlldJiBXRBAjlDsphAeo8PvcCSU/s640/2013-06-18+18.20.52.jpg" width="640" /></a></div>
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In order to be able to remove the axle without taking it completely apart, I included a shaft collar. It also prevents side-to-side motion. </div>
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<a href="http://4.bp.blogspot.com/-xPbAbq-Bqd0/UcwGsFmRNXI/AAAAAAAABpY/po-SqvA0FwE/s1600/2013-06-19+01.01.15.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://4.bp.blogspot.com/-xPbAbq-Bqd0/UcwGsFmRNXI/AAAAAAAABpY/po-SqvA0FwE/s640/2013-06-19+01.01.15.jpg" width="640" /></a></div>
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<a href="http://4.bp.blogspot.com/-bkNSvP_m8HM/UcwG1JrsCSI/AAAAAAAABpw/DQ2j428sDo0/s1600/2013-06-19+01.03.24.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://4.bp.blogspot.com/-bkNSvP_m8HM/UcwG1JrsCSI/AAAAAAAABpw/DQ2j428sDo0/s640/2013-06-19+01.03.24.jpg" width="640" /></a></div>
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<a href="http://3.bp.blogspot.com/-1LR6WQUjPHM/UcwG5SUrGhI/AAAAAAAABqA/0R2ccFyF9xg/s1600/2013-06-19+01.05.57.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://3.bp.blogspot.com/-1LR6WQUjPHM/UcwG5SUrGhI/AAAAAAAABqA/0R2ccFyF9xg/s640/2013-06-19+01.05.57.jpg" width="640" /></a></div>
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I milled out the inside so a 1/4-20 nut and bolt could barely slide inside. The bolt screws into the bottom of the camera and can be adjusted through out the entire length of the axle. I also drilled and tapped a 1/4-20 hole in the base so it could be screwed on top of a tripod. </div>
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With a mostly complete time-lapse platform, I took off to Alaska. Once there, I finished the connecting the steppers to the axles in our shop using scrap VCR/TV components and gears and chain left over from FTC.<br />
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<a href="http://1.bp.blogspot.com/-iru11oXLgVo/UcwG-DGDVzI/AAAAAAAABqY/pZSdchkhuCs/s1600/2013-06-25+16.13.46.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-iru11oXLgVo/UcwG-DGDVzI/AAAAAAAABqY/pZSdchkhuCs/s640/2013-06-25+16.13.46.jpg" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNWvBH6UbhFY3fiitHqT3x1MfOGXyqhXxugHH06bzhN7_RJHbFxD0rf4X5q_vZ_9tJgpoJHkerqI1K4o7OH1WVXPWgmclv-PCN7gHkL9uIsLuCx21gnHkpVTwBoWP-d4qVWZ1sw_qpi5M/s1600/2013-06-25+16.14.10.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNWvBH6UbhFY3fiitHqT3x1MfOGXyqhXxugHH06bzhN7_RJHbFxD0rf4X5q_vZ_9tJgpoJHkerqI1K4o7OH1WVXPWgmclv-PCN7gHkL9uIsLuCx21gnHkpVTwBoWP-d4qVWZ1sw_qpi5M/s640/2013-06-25+16.14.10.jpg" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqy2xRqZBnHqJbHsAxPK3dyW0oF6QICicSNl5NAP8WPBXY-rva24Dg4NqTN_ZJIcn6x5mM6GvqEtW2sSiGtbL6M9EdOkDiLgoqrQb_UyKrsffrMRb_XYViuZ-F34zOE75WUysTUd2nddc/s1600/2013-06-25+16.19.08.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqy2xRqZBnHqJbHsAxPK3dyW0oF6QICicSNl5NAP8WPBXY-rva24Dg4NqTN_ZJIcn6x5mM6GvqEtW2sSiGtbL6M9EdOkDiLgoqrQb_UyKrsffrMRb_XYViuZ-F34zOE75WUysTUd2nddc/s640/2013-06-25+16.19.08.jpg" width="640" /></a></div>
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The mechanism for playing VCRs is really cool, and has a bunch of tiny gears, pulleys, and belts. I crufted a few of the pulleys for the camera gantry. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDXeNcezbGYecucs5a8NEnVJq4KpUrPCYbQeidcrXDL1rV4UlaQxJFfCq0ymyAn72hfAmsSkJ5pSiQvHY8HI8wPuU5JISOKGt5CsNkpENxMCJSxGCBGVQkffY007id6nl6zyKXJ2EpWPc/s1600/2013-06-25+16.19.14.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDXeNcezbGYecucs5a8NEnVJq4KpUrPCYbQeidcrXDL1rV4UlaQxJFfCq0ymyAn72hfAmsSkJ5pSiQvHY8HI8wPuU5JISOKGt5CsNkpENxMCJSxGCBGVQkffY007id6nl6zyKXJ2EpWPc/s640/2013-06-25+16.19.14.jpg" width="640" /></a></div>
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I also re-purposed the push buttons for my custom motor controller board to enable manual control of the gantry. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQLuuWKpHB4te6-ktP0lX6Vm05W7zp6Zy2HajbDLU5W5M10S7OEZ57UA4CCbaJ0jNNbNyV6nN-6AfA33hRv9_DkT2w_2TQWkiZ8Gjmn6ea2wNycMJADkYqt76NBKukrQx6DD8Cmv4ibZQ/s1600/2013-06-25+23.03.21.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiQLuuWKpHB4te6-ktP0lX6Vm05W7zp6Zy2HajbDLU5W5M10S7OEZ57UA4CCbaJ0jNNbNyV6nN-6AfA33hRv9_DkT2w_2TQWkiZ8Gjmn6ea2wNycMJADkYqt76NBKukrQx6DD8Cmv4ibZQ/s640/2013-06-25+23.03.21.jpg" width="640" /></a></div>
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<a href="http://2.bp.blogspot.com/-pTIYXEYKCyw/UcwHjsn0r0I/AAAAAAAABsY/YEyeVECOjUA/s1600/2013-06-25+23.03.47.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://2.bp.blogspot.com/-pTIYXEYKCyw/UcwHjsn0r0I/AAAAAAAABsY/YEyeVECOjUA/s640/2013-06-25+23.03.47.jpg" width="640" /></a></div>
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I plan on replacing the VCR belts and FTC chain with timing belts when I use this in Boston. </div>
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Next, I need to build the controller board and program it to track the sun. </div>
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Jaguar Kristellerhttp://www.blogger.com/profile/08428337775851273522noreply@blogger.com1tag:blogger.com,1999:blog-2823741957408378785.post-33351943063208720722013-10-05T13:06:00.002-04:002013-10-05T20:59:34.757-04:00Electric Stater System Troubleshooting Part 2: Yes, Small Wires Limit Current<div style="text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKxNBbipq1sHMYWpSm818DtyP6C-O_IbDOd2jUZYdgec3lnjFjvMx2pAhcYFl0CN8crqMYPw9qliCWqIId4EY47t6D1-J6cpu_P0UjwOeDk0DUsOqhHkAWboTFFCf9EljI1vBhvzynEfA/s1600/2013-08-07+02.43.02.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgKxNBbipq1sHMYWpSm818DtyP6C-O_IbDOd2jUZYdgec3lnjFjvMx2pAhcYFl0CN8crqMYPw9qliCWqIId4EY47t6D1-J6cpu_P0UjwOeDk0DUsOqhHkAWboTFFCf9EljI1vBhvzynEfA/s640/2013-08-07+02.43.02.jpg" width="640" /></a></div>
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After reading and talking with some friends, I realized my earlier conclusion that the starter motor had a short is not the case. Because it turned slightly, the current is providing some torque. Therefore, it isn't shorted. If the starter motor did have a short, it would not have turned at all when I hooked the battery straight to the motor.<br />
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With that, I went out, found some containers that looked like they would do the job, and drained the engine oil and the coolant system. (Afterwards, I learned my lesson on how to find appropriate hazardous waste containers and dispose of them properly).<br />
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Draining the engine oil and coolant:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfzZ_SZBtG7Oaoq48PpTr8iVyvD4SkFL-Zwx8rR3CIt2G5B6nZnw58bW2H2Y-HkwJBh6tdIoEEM54QjEFHdcAWtt_-fhda_lvJnk9HJb57qQkUcx4cGFODjRt4YoAsRhLPZ01QXLORb5U/s1600/2013-08-07+01.12.06.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfzZ_SZBtG7Oaoq48PpTr8iVyvD4SkFL-Zwx8rR3CIt2G5B6nZnw58bW2H2Y-HkwJBh6tdIoEEM54QjEFHdcAWtt_-fhda_lvJnk9HJb57qQkUcx4cGFODjRt4YoAsRhLPZ01QXLORb5U/s640/2013-08-07+01.12.06.jpg" width="640" /></a></div>
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I unbolted the oil drain plug, and oil started gushing out. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhK-NysGyBm1nLjDXfYDcBod1L1uqrc_66PU1z7CIeBbWSTft_qctZjuz5MQKFeAYyFAOfOXRpoL5gYwUJhWe9N6ngFVfLPZp6qoyGgGSMXs_1Z3y20m8Mo-Sm13xRffXYp_C0RYat0Va4/s1600/2013-08-07+01.14.24.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhK-NysGyBm1nLjDXfYDcBod1L1uqrc_66PU1z7CIeBbWSTft_qctZjuz5MQKFeAYyFAOfOXRpoL5gYwUJhWe9N6ngFVfLPZp6qoyGgGSMXs_1Z3y20m8Mo-Sm13xRffXYp_C0RYat0Va4/s640/2013-08-07+01.14.24.jpg" width="640" /></a></div>
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That's about 2.5 Liters of engine oil. When I replace the oil filter, I'll add 3 Liters to compensate for the oil lost with the filter.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPyO8cTuL0W3qVa65qA-HtBEk-UxA_Y84qKpz2YNCJOsOc3Y3lBp4vhPpDOvTchlnI4_2L80ARqerd0_k3uPSKbWAsxMJlimRDuAJmEsuPmnGJCgt2z7exprKJ0f8N0pKXK8AqmG4Qrqs/s1600/2013-08-07+01.42.25.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjPyO8cTuL0W3qVa65qA-HtBEk-UxA_Y84qKpz2YNCJOsOc3Y3lBp4vhPpDOvTchlnI4_2L80ARqerd0_k3uPSKbWAsxMJlimRDuAJmEsuPmnGJCgt2z7exprKJ0f8N0pKXK8AqmG4Qrqs/s640/2013-08-07+01.42.25.jpg" width="478" /></a></div>
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Before I replace the coolant, I will definitely go through and clean out the coolant tank. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhUi-MTM4Cu0dJZcZrDfsLjxxCkVNXd_WAOCPqm233BKxNvllQuUtO0YodaPpDuXb4mHSsqtSYVVImJ3M5UJACDb-eLzkPMcxyd2PQNddLbNr9K10gyr3Mdz6GTCu3UPgIOh04KDoDuGi8/s1600/2013-08-07+02.43.13.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhUi-MTM4Cu0dJZcZrDfsLjxxCkVNXd_WAOCPqm233BKxNvllQuUtO0YodaPpDuXb4mHSsqtSYVVImJ3M5UJACDb-eLzkPMcxyd2PQNddLbNr9K10gyr3Mdz6GTCu3UPgIOh04KDoDuGi8/s640/2013-08-07+02.43.13.jpg" width="640" /></a></div>
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Finally after draining the oil and coolant, I could remove the hoses blocking the starter motor and proceed to unbolt the motor. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQsfz8OD_nnGwPJmUSiQRsHsiTq08zV4JwnPb9sRy02GT1bwaQIHN8S3_MYUta6TTPzvK3yK24M9OVKWsKwvrV6h6T7Ydv9Yk4hFimKzMRZRhcMEwoIftfSltASUHq9ArkW7_XYh5MUPs/s1600/2013-08-07+02.43.18.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhQsfz8OD_nnGwPJmUSiQRsHsiTq08zV4JwnPb9sRy02GT1bwaQIHN8S3_MYUta6TTPzvK3yK24M9OVKWsKwvrV6h6T7Ydv9Yk4hFimKzMRZRhcMEwoIftfSltASUHq9ArkW7_XYh5MUPs/s640/2013-08-07+02.43.18.jpg" width="640" /></a></div>
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I exposed the starter relay so I could bypass all the switches and directly start the motor with a screwdriver. </div>
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<iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='640' height='532' src='https://www.youtube.com/embed/MDt0UR4fjKo?feature=player_embedded' frameborder='0'></iframe></div>
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This is what the starter relay had been sounding like the whole time when trying to start the motorcycle with the starter switch. It would sometimes turn the motor slightly, then revert to clicking repeatedly.<br />
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I tried bypassing the relay and switches with a screwdriver. Surprisingly, it worked! Because the starter motor was no longer in the engine and didn't require as much current to turn, bypassing the switches worked.</div>
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It also worked using the switches. So the added load of the engine was causing the relay to flicker. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4h-eq1rBV-4mL85-GrYJw38n6RVXrHYeBFlbVMoM-QFHVViL-iMRBg8397yby3h0x1mVvfniBHp7XMC_P5jJaRllFLYa53w7w7ia_uwKR4rre-pqHiWQCm4Z_RGQideb7FfIv16lXpNw/s1600/2013-08-07+03.11.24.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4h-eq1rBV-4mL85-GrYJw38n6RVXrHYeBFlbVMoM-QFHVViL-iMRBg8397yby3h0x1mVvfniBHp7XMC_P5jJaRllFLYa53w7w7ia_uwKR4rre-pqHiWQCm4Z_RGQideb7FfIv16lXpNw/s640/2013-08-07+03.11.24.jpg" width="640" /></a></div>
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The solution was staring me in the face. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEis2p308dIrYYXve7NrCKrNt9FBDclscx2G4rbhL2tGC5-N0voiKjahS_pEKbP31Ns9zibrmSLncXx9ysSG-vggQr83oAwFcFHot4q7LJ64IGolIX77ypeBvD4dg9f4KhxRGqcvyXThrT4/s1600/2013-08-07+03.11.11.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEis2p308dIrYYXve7NrCKrNt9FBDclscx2G4rbhL2tGC5-N0voiKjahS_pEKbP31Ns9zibrmSLncXx9ysSG-vggQr83oAwFcFHot4q7LJ64IGolIX77ypeBvD4dg9f4KhxRGqcvyXThrT4/s640/2013-08-07+03.11.11.jpg" width="640" /></a></div>
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Ben and Dgonz thought maybe the thin alligator clip wires were limiting the current, and suggested moving it closer to the motor. </div>
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<iframe allowfullscreen='allowfullscreen' webkitallowfullscreen='webkitallowfullscreen' mozallowfullscreen='mozallowfullscreen' width='640' height='532' src='https://www.youtube.com/embed/DkK87McqcR8?feature=player_embedded' frameborder='0'></iframe></div>
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That fixed it completely! The starter motor can now turn the engine without sketchily using a screwdriver to bypass the switches. So what was wrong with this motorcycle!? Turned out to just be the battery. Before investing any more money into this project, I'm trying to get a title. Once I get a title, I'll replace the battery and make some carbon fiber fairings.</div>
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In the meantime, I went and picked up the KLR 650 my Dad drove down to Wilkes-Barre, Pennsylvania last year on our way over to Boston for school. I got to spend a great weekend with my Dad's side of the family. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjACPgvQGWRCqTIqfmaT6vL5WO1GzPYB19X5n1YXs0Cs8xVL4gjpC6VVZy9bweHKHwnJr93idjcQdiqkWxoanFLzZqEc51KGinPm5aCTNNEPQEJLPSxdfxm_7ckNRBbDmK5POhUZ8lAH9Q/s1600/2013-08-02+16.21.16.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjACPgvQGWRCqTIqfmaT6vL5WO1GzPYB19X5n1YXs0Cs8xVL4gjpC6VVZy9bweHKHwnJr93idjcQdiqkWxoanFLzZqEc51KGinPm5aCTNNEPQEJLPSxdfxm_7ckNRBbDmK5POhUZ8lAH9Q/s640/2013-08-02+16.21.16.jpg" width="640" /></a></div>
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Of all things to cruft, a helmet isn't one of them. Investing in a good helmet can save a life. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUvsVxhPwas-4AlMcYoky4dqNjnbqCJ3AGK6SgiZOtFv_Ih_A1V2fcgS9-N9uZET7Lw2oO1auymAi0QBjbmJAllDrrQ2fwRyB-PIxG1jJ9lwI6kUZFePLm4H6uQrMhZs46Gzie-FzNrls/s1600/2013-08-02+19.50.13.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUvsVxhPwas-4AlMcYoky4dqNjnbqCJ3AGK6SgiZOtFv_Ih_A1V2fcgS9-N9uZET7Lw2oO1auymAi0QBjbmJAllDrrQ2fwRyB-PIxG1jJ9lwI6kUZFePLm4H6uQrMhZs46Gzie-FzNrls/s640/2013-08-02+19.50.13.jpg" width="640" /></a></div>
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Fueling up. This was actually the first time I ever put gas in a vehicle by myself. I have this goal to never put gas in a vehicle that doesn't get over 50 MPG. So far I'm abiding by it.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhc1tPz4XgET5W2n1l17V3WoTs91Dsly4OiI4hRqZbd3TD5AulokV3yKhsFHENGMwoDJt6DScERZH9b_kH81ICnSVfp_V_9Rvir_Mzst0CZS_9kigLc8_rr9T5kemLG1DqVOBzH7b_MJEI/s1600/2013-08-04+17.20.43.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhc1tPz4XgET5W2n1l17V3WoTs91Dsly4OiI4hRqZbd3TD5AulokV3yKhsFHENGMwoDJt6DScERZH9b_kH81ICnSVfp_V_9Rvir_Mzst0CZS_9kigLc8_rr9T5kemLG1DqVOBzH7b_MJEI/s640/2013-08-04+17.20.43.jpg" width="640" /></a></div>
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihGv6nnCWPyVlmKS9KSfmz_0wHQ6SdD8AwLUnWU6g43l-v30gi0-LSYwH-_fZrUJCIppzlGG8rEJ88Zvmqos79WD_38lrnYGw8Cn7ztIcsuaKCjUPNJ5FivwY9xd_vUgLKtrWh3e2844s/s1600/2013-08-04+20.04.41.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihGv6nnCWPyVlmKS9KSfmz_0wHQ6SdD8AwLUnWU6g43l-v30gi0-LSYwH-_fZrUJCIppzlGG8rEJ88Zvmqos79WD_38lrnYGw8Cn7ztIcsuaKCjUPNJ5FivwY9xd_vUgLKtrWh3e2844s/s640/2013-08-04+20.04.41.jpg" width="640" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Somewhere between Syracuse and Boston</td></tr>
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg80XlIAFVlnl1ek-_7JIyf-raP0Mf9tdsUdsMO_8QSejmwx_ZvsU_kzNUInAavkdmjfebGwVGKCMhnseF4o76AdJnYqqK3Ur1c44bNw9GMHZi6HVu2hhz7Ltgp-3NwfiqL9EPOB2xsJmw/s1600/2013-08-11+00.06.18.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg80XlIAFVlnl1ek-_7JIyf-raP0Mf9tdsUdsMO_8QSejmwx_ZvsU_kzNUInAavkdmjfebGwVGKCMhnseF4o76AdJnYqqK3Ur1c44bNw9GMHZi6HVu2hhz7Ltgp-3NwfiqL9EPOB2xsJmw/s640/2013-08-11+00.06.18.jpg" width="640" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Back in Boston... with two motorcycles</td></tr>
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The ride was fantastic! Passing semi-trucks was absolutely terrifying, but near the end I think I got the hang of it. The wind is sometimes hard to deal with. My heart jumped every time I saw flashing blue and red lights. Toll booths are a bit hard on a motorcycle. I decided to ignore what other's might think as I'm taking for ever digging money out of my pockets and just focus of being safe. I can never be too safe. This ride was the first time I had ever ridden a motorcycle on the road without my Dad, and for an extended period of time. I've never driven that far in a car. All in all, it was a fun ride and I made it back safely.Jaguar Kristellerhttp://www.blogger.com/profile/08428337775851273522noreply@blogger.com2tag:blogger.com,1999:blog-2823741957408378785.post-85549442312055565072013-10-05T12:58:00.002-04:002013-10-05T21:09:07.048-04:00Repairing a 42" Plasma LG TV<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgES1wuBHWDZbw6aTAJGZxhifiBDBwNa-xxRXfUkWNp2jVGMROqYVMtsKlnQMOivPPPKGrxS9QQlET1_mqRVKwt5TtvS6j8e1PdoDrrP92AtCLSJkVHbDKTBzJrBSQOslEMCYPq5YubmUE/s1600/2013-05-27+03.47.42.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgES1wuBHWDZbw6aTAJGZxhifiBDBwNa-xxRXfUkWNp2jVGMROqYVMtsKlnQMOivPPPKGrxS9QQlET1_mqRVKwt5TtvS6j8e1PdoDrrP92AtCLSJkVHbDKTBzJrBSQOslEMCYPq5YubmUE/s640/2013-05-27+03.47.42.jpg" width="640" /></a></div>
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A couple days after the end of <a href="http://www.etotheipiplusone.net/?p=2730" target="_blank">2.00 Gokart</a> there was a huge supply of electric vehicle goodies. Unfortunately, I was at the final performance of <a href="http://web.mit.edu/roadkill/www/" target="_blank">Roadkill Buffet</a>, "MIT's premier improv comedy troupe", while most of the good cruft got crufted. Some of the earlier crufters got their hands on a 42" plasma LG TV and tried fixing it on the spot (thinking it was just a blown fuse). By the time I got there, they were giving up on it. So, being the naive and ambitious person I am, I decided to carry it back to EC and learn a bit about how plasma televisions work. Thankfully Ed Moriarty was there cleaning out the 2.007 Underwater Vehicle section's materials, and was able to drive the TV over to East Campus. After some debugging and replacing some parts, I ended up with a pretty big monitor. </div>
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<a name='more'></a>Keep in mind, this all happened a couple months ago. I'm spending a whole day blogging in an effort to catch up and keep a consistent post rate.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEyy9ELLIupnxcXcoB59-ipPwBuZR4aKat57dJ6LFiRmR0wTF3l6qoC8z4jgZLWiMOeTXf36-I2i4KAXCysF1HvdyROYuiHstulgMAZbe83HPD6229sRXhbd5kh1HRjVmoKguTNxUMshc/s1600/2013-05-30+16.01.49.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEyy9ELLIupnxcXcoB59-ipPwBuZR4aKat57dJ6LFiRmR0wTF3l6qoC8z4jgZLWiMOeTXf36-I2i4KAXCysF1HvdyROYuiHstulgMAZbe83HPD6229sRXhbd5kh1HRjVmoKguTNxUMshc/s640/2013-05-30+16.01.49.jpg" width="640" /></a></div>
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SYMPTOMS:<br />
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Blown fuse (FS152) on the Y-Sustain (Y-SUS) board near the power supply connection.<br />
Bulging Capacitors 250WV 330uF (C154 and C153).<br />
Screen doesn't respond to anything.<br />
Power switch LED turns on followed by a quiet relay click.<br />
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Since the previous crufters tried switching the blown fuses to no avail, I thought maybe the capacitors were the problem. I spent a good portion of a day going through all the cruft sites at MIT looking for power supplies. </div>
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<a href="http://1.bp.blogspot.com/-ajtzBaDbHIg/UavtLXNIgQI/AAAAAAAABWQ/LQh6ZUI4pFo/s1600/2013-05-27+15.44.14.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-ajtzBaDbHIg/UavtLXNIgQI/AAAAAAAABWQ/LQh6ZUI4pFo/s640/2013-05-27+15.44.14.jpg" width="640" /></a></div>
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I eventually found a capacitor that was rated for 250WV and over 330uF. <a href="http://isopack.blogspot.com/" target="_blank">Bailey</a> and the internet said that capacitors with the same working voltage and higher capacitance would work. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2YfMSbfPpeBpm-pFf9EE2xDOBLSE_ORU45vP-l7qONAqpxoSZka3iuE9DP9mugwJcLNW0HAIaN_3aeqwnclTvLGlEW-tweQFFDfSmxZ0CLkswVNYRVOqXFqdSJydE5iKJeRmCjkjwmBI/s1600/2013-05-27+03.47.51.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi2YfMSbfPpeBpm-pFf9EE2xDOBLSE_ORU45vP-l7qONAqpxoSZka3iuE9DP9mugwJcLNW0HAIaN_3aeqwnclTvLGlEW-tweQFFDfSmxZ0CLkswVNYRVOqXFqdSJydE5iKJeRmCjkjwmBI/s640/2013-05-27+03.47.51.jpg" width="640" /></a></div>
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Old bulging capacitors.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgL7ZqdSMuzkiVKyw2hLyzbKAXNYYSUVmqPozdrAw-fVXuuCgexifmsV42Ea7WLIRRb0mwharDoylC1gy78zC5yR6_te7lL2e0pyGrEVh2pbWsJm8fv-jl625REP2HcwxHQNBv39n1ufu8/s1600/2013-05-28+18.34.04.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgL7ZqdSMuzkiVKyw2hLyzbKAXNYYSUVmqPozdrAw-fVXuuCgexifmsV42Ea7WLIRRb0mwharDoylC1gy78zC5yR6_te7lL2e0pyGrEVh2pbWsJm8fv-jl625REP2HcwxHQNBv39n1ufu8/s640/2013-05-28+18.34.04.jpg" width="640" /></a></div>
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<a href="http://2.bp.blogspot.com/-g94ZoZKjDl0/UavtPDkOxtI/AAAAAAAABXY/kVUzzF4KpJs/s1600/2013-05-28+18.39.43.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://2.bp.blogspot.com/-g94ZoZKjDl0/UavtPDkOxtI/AAAAAAAABXY/kVUzzF4KpJs/s640/2013-05-28+18.39.43.jpg" width="640" /></a></div>
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<a href="http://1.bp.blogspot.com/-GhrOzgwM67A/UavtPyBw_eI/AAAAAAAABXw/JVbgWTR-lzM/s1600/2013-05-28+19.02.21.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-GhrOzgwM67A/UavtPyBw_eI/AAAAAAAABXw/JVbgWTR-lzM/s640/2013-05-28+19.02.21.jpg" width="640" /></a></div>
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<a href="http://1.bp.blogspot.com/-hqvP8PAHU_0/Ue9TsHVvDaI/AAAAAAAAB00/E-imSJ82MHk/s1600/2013-06-07+23.19.59.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-hqvP8PAHU_0/Ue9TsHVvDaI/AAAAAAAAB00/E-imSJ82MHk/s640/2013-06-07+23.19.59.jpg" width="640" /></a></div>
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After replacing the capacitors, I tried testing the screen again.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEyy9ELLIupnxcXcoB59-ipPwBuZR4aKat57dJ6LFiRmR0wTF3l6qoC8z4jgZLWiMOeTXf36-I2i4KAXCysF1HvdyROYuiHstulgMAZbe83HPD6229sRXhbd5kh1HRjVmoKguTNxUMshc/s1600/2013-05-30+16.01.49.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEyy9ELLIupnxcXcoB59-ipPwBuZR4aKat57dJ6LFiRmR0wTF3l6qoC8z4jgZLWiMOeTXf36-I2i4KAXCysF1HvdyROYuiHstulgMAZbe83HPD6229sRXhbd5kh1HRjVmoKguTNxUMshc/s640/2013-05-30+16.01.49.jpg" width="640" /></a> </div>
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To test the screen and whether or not the sound worked, I hooked up W5's GameCube with Super Smash Bros running. The TV has great speakers; it's just the video that's dead. </div>
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Internet! I'm suspecting either a problem the power supply supplying to much current, or a faulty component on the Y-Sustain board causing a surge from the power supply.<br />
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<a href="http://4.bp.blogspot.com/-7HsPjeQrUdY/UavtRTq5M2I/AAAAAAAABYI/ybydm2NarMg/s1600/2013-05-28+22.40.57.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="640" src="http://4.bp.blogspot.com/-7HsPjeQrUdY/UavtRTq5M2I/AAAAAAAABYI/ybydm2NarMg/s640/2013-05-28+22.40.57.jpg" width="478" /></a></div>
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A quick Google search for "YSUS 6871QYH051P FS152" resulted in a great blog post for troubleshooting bad IPMs (Intelligent Power Modules). <a href="http://blog.coppelltvrepair.com/2011/04/how-to-test-stk795-518-ysus-ipm-for.html">The Coppell TV repair</a> online blog tested Sanyo's STK795-518 (which is the IPM used in Y-SUS board LJ92-01200A), but it also works for many Y-SUS IPMs. <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZ_xvlxYVPildOisrOXk4xi7zom9G6Yn7QnAFv-5SVsuA0k_qOELqhINdG81HODhIOTVivN3YS-2LAEU1ng6X5CL02nxbqTgMjP8khWmEAZlFf1Gjrxf_m1hJgvhYstbUFLJin0RJIQ5g/s1600/2013-06-02+19.36.23.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZ_xvlxYVPildOisrOXk4xi7zom9G6Yn7QnAFv-5SVsuA0k_qOELqhINdG81HODhIOTVivN3YS-2LAEU1ng6X5CL02nxbqTgMjP8khWmEAZlFf1Gjrxf_m1hJgvhYstbUFLJin0RJIQ5g/s640/2013-06-02+19.36.23.jpg" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqmmN23-VX02751uKQgNAuiuSNpike0xYunFUaExh71zjMh2boFXLM3bBB-THzszWQ-t_Cr8VkkK44yi2I4ilmqKEvDXrC6CL75nVEq48V582T9fcXd_z5LPgk8uMf9hhnBbxOhQLTipI/s1600/2013-06-02+19.37.02.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqmmN23-VX02751uKQgNAuiuSNpike0xYunFUaExh71zjMh2boFXLM3bBB-THzszWQ-t_Cr8VkkK44yi2I4ilmqKEvDXrC6CL75nVEq48V582T9fcXd_z5LPgk8uMf9hhnBbxOhQLTipI/s640/2013-06-02+19.37.02.jpg" width="640" /></a></div>
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One easy way to fix the board would be to buy a new one. However, because it's faster it costs more; most sites list $100+ (not including shipping) for a functioning Y-SUS board. There's a programmer's saying "good, fast, cheap: pick any two". If soldering isn't your thing and you don't mind paying for it, this is probably the safest/fastest way to repair your television.<br />
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Another cheaper alternative to repairing the board is to buy the specific components that are dead. Most of the board is still good (or so I thought). I bought a <a href="http://www.ebay.com/itm/110864784729?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649" target="_blank">new IPM</a> and the <a href="http://www.ebay.com/itm/130683000778?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1497.l2649" target="_blank">proper capacitors</a> for a total repair cost of $37.50<br />
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Shipping...<br />
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I replaced the fuses with 4A 250V fuse from CSAIL and checked them to make sure they wouldn't blow before I put the nice IPM on the Y-SUS board.<br />
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="http://4.bp.blogspot.com/-Ii8tGPtmRGc/Ue9Ts6Aht-I/AAAAAAAAB1A/gpYDzsdzD3w/s1600/2013-06-07+23.22.36.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="478" src="http://4.bp.blogspot.com/-Ii8tGPtmRGc/Ue9Ts6Aht-I/AAAAAAAAB1A/gpYDzsdzD3w/s640/2013-06-07+23.22.36.jpg" width="640" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">New IPM :D</td></tr>
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<a href="http://4.bp.blogspot.com/-BOF1wbBzdoM/Ue9TuMYlHnI/AAAAAAAAB1I/WM2Emx1GVeU/s1600/2013-06-07+23.22.51.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://4.bp.blogspot.com/-BOF1wbBzdoM/Ue9TuMYlHnI/AAAAAAAAB1I/WM2Emx1GVeU/s640/2013-06-07+23.22.51.jpg" width="640" /></a></div>
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Once the new IPM came, I did the same continuity check to ensure that the old IPM was definitely a problem.</div>
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<a href="http://1.bp.blogspot.com/-VScgLDjjXTg/Ue9TvPFJI0I/AAAAAAAAB1Q/YKIqO4JOu4o/s1600/2013-06-07+23.23.18.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-VScgLDjjXTg/Ue9TvPFJI0I/AAAAAAAAB1Q/YKIqO4JOu4o/s640/2013-06-07+23.23.18.jpg" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUigo-CQtHm_a49oY2b0eU-d05QsHOGZgVVRpj_Y56n5LDXtIF2-tg4lNjr_pte9HiBdT1wzfzzKwMhRNldsJizYqWKIvd6TSlzjk5K8Cmp1GXAaFhUF9Z5P8xpZqyNvsVXd0aseY1a5w/s1600/2013-06-07+23.26.14.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUigo-CQtHm_a49oY2b0eU-d05QsHOGZgVVRpj_Y56n5LDXtIF2-tg4lNjr_pte9HiBdT1wzfzzKwMhRNldsJizYqWKIvd6TSlzjk5K8Cmp1GXAaFhUF9Z5P8xpZqyNvsVXd0aseY1a5w/s640/2013-06-07+23.26.14.jpg" width="640" /></a></div>
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It checked out! Time to anti-solder.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCTSRC7wHZPvgjbXaZDsKAOb-xtG6Yk6CSEefiug4FHG17_No58XFsa3qFM52WIJtUhbTTPcJ6ggpDNxJfQI6SnizxkUl5R0DGYa43w9O85NvltPAm3lj5QmMBhQdVH2ISuWuBfe24jZk/s1600/2013-06-09+19.26.23.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhCTSRC7wHZPvgjbXaZDsKAOb-xtG6Yk6CSEefiug4FHG17_No58XFsa3qFM52WIJtUhbTTPcJ6ggpDNxJfQI6SnizxkUl5R0DGYa43w9O85NvltPAm3lj5QmMBhQdVH2ISuWuBfe24jZk/s640/2013-06-09+19.26.23.jpg" width="640" /></a></div>
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I used MITER's big soldering iron, because the little iron I had didn't put out enough heat. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOiUbaablRGgT__Kx3LM9rOKHu7StyS0ObWkBw9M9pA7Z887sq46HLoW6iGK63Fy45OxKQiKwuf1j_TKj442BJdjLsm_qXyfaIcYDzwxkQcduHkNl7us9xvbvxUTIgxEWSa9cu6oVHU9Y/s1600/2013-06-09+19.25.40.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOiUbaablRGgT__Kx3LM9rOKHu7StyS0ObWkBw9M9pA7Z887sq46HLoW6iGK63Fy45OxKQiKwuf1j_TKj442BJdjLsm_qXyfaIcYDzwxkQcduHkNl7us9xvbvxUTIgxEWSa9cu6oVHU9Y/s640/2013-06-09+19.25.40.jpg" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgK5VMKjNHzoF7MBzMLkLAK9vJgvEy6euhWNTKAV86bhdrvnga9tIad_HEg6bjg64GWXGiU_oLfaE3vjIJ-Y36-qJXas6BR7OEUE_zfd8uTy42Tp0_CXONZFM0LPyTONdxbCSfQ0G5Btrc/s1600/2013-06-09+19.28.48.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgK5VMKjNHzoF7MBzMLkLAK9vJgvEy6euhWNTKAV86bhdrvnga9tIad_HEg6bjg64GWXGiU_oLfaE3vjIJ-Y36-qJXas6BR7OEUE_zfd8uTy42Tp0_CXONZFM0LPyTONdxbCSfQ0G5Btrc/s640/2013-06-09+19.28.48.jpg" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhA5qMv3gBo899qH1ZRzWWz0gJRsTK_WJWW47byPdRiLCgbHVWjyfmH08VHjFH_lz-JMDD0S_ateLtbcYapks1ulvbjHYWy40JT2eZGtCgvPyZs6P5rW6dV3Am8i4K10tC3wOF6szH82DU/s1600/2013-06-09+21.23.24.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhA5qMv3gBo899qH1ZRzWWz0gJRsTK_WJWW47byPdRiLCgbHVWjyfmH08VHjFH_lz-JMDD0S_ateLtbcYapks1ulvbjHYWy40JT2eZGtCgvPyZs6P5rW6dV3Am8i4K10tC3wOF6szH82DU/s640/2013-06-09+21.23.24.jpg" width="640" /></a></div>
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Rubbing alcohol is great at removing the old thermal paste from the heat sink. I replaced the old paste with some Arctic Silver high-denisty polysynthetic silver using an old USTA Membership card.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj-LpAPrQti1MkU0mz_AYYH7oZT038bRRio4JVweKkkHh7YwzS3vXOXg_XbAx-YuCOHh1arl40U_D2Z2740wcb5M78vMaOwrBQMxSVk9PiH1iMYlTuNqgUVe7zjAcFo5SAj5iYmD7oX-RE/s1600/2013-06-09+21.22.58.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj-LpAPrQti1MkU0mz_AYYH7oZT038bRRio4JVweKkkHh7YwzS3vXOXg_XbAx-YuCOHh1arl40U_D2Z2740wcb5M78vMaOwrBQMxSVk9PiH1iMYlTuNqgUVe7zjAcFo5SAj5iYmD7oX-RE/s640/2013-06-09+21.22.58.jpg" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAZvbCguzSQG6is6pvUQkjMWOBwc8XQx7C4JzGsaNGxpuCUWVe_2Vc7sMc0Di39iYVpWz5j37UexsH9BuvXNCXXuxKrNzS8QixYxK1WjvNrY5tLrXg_FkHF1V96J1O0Kt44Mjca00sECE/s1600/2013-06-09+21.45.27.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAZvbCguzSQG6is6pvUQkjMWOBwc8XQx7C4JzGsaNGxpuCUWVe_2Vc7sMc0Di39iYVpWz5j37UexsH9BuvXNCXXuxKrNzS8QixYxK1WjvNrY5tLrXg_FkHF1V96J1O0Kt44Mjca00sECE/s640/2013-06-09+21.45.27.jpg" width="640" /></a></div>
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While soldering the new IPM on, I also switched out the temporary 250WV 470uF capacitors with 250WV 330uF. I didn't want to risk the different capacitors messing up the new (most expensive part of this project) IPM. I don't want to wait another week.</div>
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Sooo...</div>
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It turns out that the IPM wasn't the only problem. When I replaced it, the screen started warming up like it was just about to flicker on... then blue sparks and smoke. These sparks happened in a location with tiny surface mounted components. After further research, I decided investing in a one-hundred dollar Y-Sustain board would fix the problem with a high degree of certainty. </div>
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Shipping...</div>
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While waiting for the new Y-SUS board to come in, I built a mount modification to fit my dorm room bed. </div>
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<a href="http://1.bp.blogspot.com/-xvp0ODpHgOI/UexpB3pB5QI/AAAAAAAABx0/TqyKyKZPik8/s1600/2013-07-10+01.17.54.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-xvp0ODpHgOI/UexpB3pB5QI/AAAAAAAABx0/TqyKyKZPik8/s640/2013-07-10+01.17.54.jpg" width="640" /></a></div>
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The mount that came with the television had a hole arrangement that fit the 2 x 4 bed frame loft. </div>
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<a href="http://2.bp.blogspot.com/-W9CSEItVomI/UexpEsdOm-I/AAAAAAAAByM/t1JTTZyq7Bg/s1600/2013-07-10+01.18.24.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://2.bp.blogspot.com/-W9CSEItVomI/UexpEsdOm-I/AAAAAAAAByM/t1JTTZyq7Bg/s640/2013-07-10+01.18.24.jpg" width="640" /></a></div>
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I found some 5/8" x 4" aluminum stock at MITERS that I could side tap to bolt to the tv mount.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj3hv7mU_khxG9OxHSFf27S-PuRyiSloum0Oo8OZM2XjyJ1HG7WWDF2q0KcVnfn6kdrMhqAHuNSuA9Y9b75I2jcWMBB2XMAfqxc_8gzUt1bQ610DoOO25nT7aSsFBLl0W3ZdWSS2IS86Xw/s1600/2013-07-11+00.11.04.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj3hv7mU_khxG9OxHSFf27S-PuRyiSloum0Oo8OZM2XjyJ1HG7WWDF2q0KcVnfn6kdrMhqAHuNSuA9Y9b75I2jcWMBB2XMAfqxc_8gzUt1bQ610DoOO25nT7aSsFBLl0W3ZdWSS2IS86Xw/s640/2013-07-11+00.11.04.jpg" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEga8kQttexQm3SfB1tisMsn-G2025RbIvDsT-ZcBKUKR4algOnN5HUtp2QuHPX6rVBikZ-FQsLISTszJqI7Wp9Y0CBlM6Rk7IPY5OJNoKUWrsDDp-GqLouYXmTgqFn0hBk-6UP2zYANk70/s1600/2013-07-11+00.20.05.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEga8kQttexQm3SfB1tisMsn-G2025RbIvDsT-ZcBKUKR4algOnN5HUtp2QuHPX6rVBikZ-FQsLISTszJqI7Wp9Y0CBlM6Rk7IPY5OJNoKUWrsDDp-GqLouYXmTgqFn0hBk-6UP2zYANk70/s640/2013-07-11+00.20.05.jpg" width="640" /></a></div>
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I clamped them together (in opposite orientations) and drilled holes that were offset from the center axis by 1/2". When I finished, I flipped one over so the hole pattern was mirrored. This would prevent the screws from colliding when attaching it to the loft. </div>
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<a href="http://2.bp.blogspot.com/-a-I_6CHRAnA/UexpHofTjXI/AAAAAAAAByk/CJCYcXqHsms/s1600/2013-07-11+00.34.46.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://2.bp.blogspot.com/-a-I_6CHRAnA/UexpHofTjXI/AAAAAAAAByk/CJCYcXqHsms/s640/2013-07-11+00.34.46.jpg" width="640" /></a></div>
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I drilled and tapped side holes for 4" 7/16 bolts. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYOqnGd-Fi3kONnykwiOHsHirarg2NcXDDdSJ0_EuwhjVy1wFZ0eqcYt1sSEpEG97Y49huHA4CorsBpr3G1K4RCCp0QoxB_LnJh4EJxXS5hoN9WAIZzuCb4IV0sEmVgpVUbyjWzUx_ABk/s1600/2013-07-11+01.06.57.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYOqnGd-Fi3kONnykwiOHsHirarg2NcXDDdSJ0_EuwhjVy1wFZ0eqcYt1sSEpEG97Y49huHA4CorsBpr3G1K4RCCp0QoxB_LnJh4EJxXS5hoN9WAIZzuCb4IV0sEmVgpVUbyjWzUx_ABk/s640/2013-07-11+01.06.57.jpg" width="640" /></a></div>
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And countersunk the holes for the wood screws to set into. </div>
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<a href="http://2.bp.blogspot.com/-4tcYt3Nirsk/UexpJP5cizI/AAAAAAAABy0/w66yJXjEsag/s1600/2013-07-11+01.24.01.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://2.bp.blogspot.com/-4tcYt3Nirsk/UexpJP5cizI/AAAAAAAABy0/w66yJXjEsag/s640/2013-07-11+01.24.01.jpg" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLZNoyDBTW5qHM6bDkP1cTF9XbXtJGJ_PaDJD6FN-4GA8egWNTgg99FpxjA3GQ11eGnLJwmXZpEg97eApzAn4SFmNai66rN80041lUwmVKIuECb4gc8qiGn1Yk-DoDAVV4KBJSeXTDKas/s1600/2013-07-11+01.24.31.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLZNoyDBTW5qHM6bDkP1cTF9XbXtJGJ_PaDJD6FN-4GA8egWNTgg99FpxjA3GQ11eGnLJwmXZpEg97eApzAn4SFmNai66rN80041lUwmVKIuECb4gc8qiGn1Yk-DoDAVV4KBJSeXTDKas/s640/2013-07-11+01.24.31.jpg" width="640" /></a></div>
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<a href="http://4.bp.blogspot.com/-BZjsRmpyipo/UexpNvfBxfI/AAAAAAAABzY/XZ-LbKqhjCg/s1600/2013-07-12+02.13.32.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://4.bp.blogspot.com/-BZjsRmpyipo/UexpNvfBxfI/AAAAAAAABzY/XZ-LbKqhjCg/s640/2013-07-12+02.13.32.jpg" width="640" /></a></div>
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Assembled and attached to the bed frame. Now all that's left is plugging in the new Y-SUS board when it arrives and hope that it fixes the dead screen problem. </div>
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"[Fred Desk] Package at East Campus Desk [2013-07-18]"</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgsRNqw-WfwNYro5q0DmJpSd9uENB9ifYuWuO6KXvnjRYZKTYqebcmJSaPgZgW-ey6mYkYfuP6UtFG6rzi3oHoCzg6pE6qMkU3OqNPxjyNWXLfrjn6tscycPAlRMUcG-6CjP2HtTp6hC6g/s1600/2013-07-18+20.57.12.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgsRNqw-WfwNYro5q0DmJpSd9uENB9ifYuWuO6KXvnjRYZKTYqebcmJSaPgZgW-ey6mYkYfuP6UtFG6rzi3oHoCzg6pE6qMkU3OqNPxjyNWXLfrjn6tscycPAlRMUcG-6CjP2HtTp6hC6g/s640/2013-07-18+20.57.12.jpg" width="640" /></a></div>
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
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<tr><td class="tr-caption" style="text-align: center;">Old Y-SUS</td></tr>
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEif6300xBdiObDhXwT8N4i03cpq4xrewbYNu3rjC0dnzId9cCmmeZ0vZ4IYd8AXHaHjklvijf89rlSUNsGqDphElUnFFmLI2azQwDFpTNqA6tPCiuS8RYB3VoOFbVC8BV4ls7I_ZBOxmNw/s1600/2013-07-18+21.37.54.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEif6300xBdiObDhXwT8N4i03cpq4xrewbYNu3rjC0dnzId9cCmmeZ0vZ4IYd8AXHaHjklvijf89rlSUNsGqDphElUnFFmLI2azQwDFpTNqA6tPCiuS8RYB3VoOFbVC8BV4ls7I_ZBOxmNw/s640/2013-07-18+21.37.54.jpg" width="640" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">New Y-SUS</td></tr>
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Before I plugged the new board in, I did a few more tests with the multimeter. I hadn't ruled out the possibility that the Power Supply board wasn't the cause of the blown fuse. It could have either been the IPM failing and drawing too much current or the Power Supply surging and pushing too much through the fuse causing the IPM to short somewhere. After checking the output voltages from the Power Supply and determining them safe, I plugged in the new board and tested it. </div>
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I've never been happier to see static!<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1C9FGiuXNqpk_SllDmjTwNM5v3wTKySPCsJ9PQyYoo47JTRMOTpyaEACG9WjZGogAeL0PQbv70Z0LQWWIkMSHkJ3NO8mHOUYVkLIgY-I2Vmfjtog1ZXYV4CoePGx6XRoJpK9COcQ5nwo/s1600/2013-07-21+21.20.43.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1C9FGiuXNqpk_SllDmjTwNM5v3wTKySPCsJ9PQyYoo47JTRMOTpyaEACG9WjZGogAeL0PQbv70Z0LQWWIkMSHkJ3NO8mHOUYVkLIgY-I2Vmfjtog1ZXYV4CoePGx6XRoJpK9COcQ5nwo/s640/2013-07-21+21.20.43.jpg" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgi8BvZi_RA4AR2xJ_OCTRnbzi8nF3KC1iaGznzMWGNNNifObR5GYtUjpcuZJqRLNNSrof-wV9Qx8W4WrEK7AEcj4GZxG7XQdkUS_uDmH4-__AAHubFlQ3TKNBNm5VI-PvC8eEyYwY_mec/s1600/2013-07-21+21.45.12.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgi8BvZi_RA4AR2xJ_OCTRnbzi8nF3KC1iaGznzMWGNNNifObR5GYtUjpcuZJqRLNNSrof-wV9Qx8W4WrEK7AEcj4GZxG7XQdkUS_uDmH4-__AAHubFlQ3TKNBNm5VI-PvC8eEyYwY_mec/s640/2013-07-21+21.45.12.jpg" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdnsL7y1AkDTloUu-fNjgTDB3N1yi9rmt7geIlXqBNPI_kZdtjVl7ZfRdcDFngq0kxL8mIjwr0IA-kqmlEvBSGGsPPSQaADxF4tCcwBMfzVDaU72NqC_bvP-AleDz68hhjJ-AS-rZliNM/s1600/2013-07-21+21.46.55.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdnsL7y1AkDTloUu-fNjgTDB3N1yi9rmt7geIlXqBNPI_kZdtjVl7ZfRdcDFngq0kxL8mIjwr0IA-kqmlEvBSGGsPPSQaADxF4tCcwBMfzVDaU72NqC_bvP-AleDz68hhjJ-AS-rZliNM/s640/2013-07-21+21.46.55.jpg" width="640" /></a></div>
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghyphenhyphenyTk71MQ42yD1ORJMHAZpNqjcSGyUV9QHR0g92TQwjU1YbhRNGplyq8klO5qZlJyqNqHELz9Yq5NJEgK7qMYWxILsmhJkcTBqdop5PiYmDyzGPBTX6Ud7nKFl6DwWlUEKTinhZyHjuo/s1600/2013-07-21+15.35.19.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghyphenhyphenyTk71MQ42yD1ORJMHAZpNqjcSGyUV9QHR0g92TQwjU1YbhRNGplyq8klO5qZlJyqNqHELz9Yq5NJEgK7qMYWxILsmhJkcTBqdop5PiYmDyzGPBTX6Ud7nKFl6DwWlUEKTinhZyHjuo/s640/2013-07-21+15.35.19.jpg" width="640" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Mounted and working LG TV</td></tr>
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I finished screwing in the back panel, and mounted to my bed. All setup and ready for <a href="http://stream-tv.me/watch-suits-online/" target="_blank">Suits</a>.<br />
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After having a ton of fun watching too much TV and catching up on too many shows, summer time came to an end. I moved back onto Fifth West, which meant carrying it up four flights of stairs.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzvSD8vzEIta21A2jjPOTF11YaMYjzWsglNhMSA3EXmDUCHGLAFp7vcBF1sSic59JAuMtTP4ZxIQ8jURSb9CGUmNLTGoUg1wAZsyWhLVu2N1vzr3v5BJjOH50v5Tgh9OO54uXYGCuxGh0/s1600/IMG_2618.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzvSD8vzEIta21A2jjPOTF11YaMYjzWsglNhMSA3EXmDUCHGLAFp7vcBF1sSic59JAuMtTP4ZxIQ8jURSb9CGUmNLTGoUg1wAZsyWhLVu2N1vzr3v5BJjOH50v5Tgh9OO54uXYGCuxGh0/s640/IMG_2618.JPG" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjRGTPI-m1GP1IiGzyFT1biLhXIG-kVwrp__X4h1ICgTxmCpG22YVKl_Oskw_JX3Vskh9GXHVSQrGTwP8HJPo0tyttC-xDqRArpQRabfkiRsT5jkkWOvwPLgZeNSXYs2BQUbeZmlrel9o/s1600/IMG_2617.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjjRGTPI-m1GP1IiGzyFT1biLhXIG-kVwrp__X4h1ICgTxmCpG22YVKl_Oskw_JX3Vskh9GXHVSQrGTwP8HJPo0tyttC-xDqRArpQRabfkiRsT5jkkWOvwPLgZeNSXYs2BQUbeZmlrel9o/s640/IMG_2617.JPG" width="640" /></a></div>
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Raku, my room-mate freshman year, moved to ADPhi, and left me with a single. I decided to keep the other bed for guests which has been quite useful. Also, the board spanning the two lofts is a perfect space for a giant TV. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj18a9_UtoZJP51jWDMmmDNifd3tm0K5OwUIYPuwFLlBI4jn-zT4Clz4c0mcvoc1yOIOMISc6jxcm_RbgoOYz6XA328VMn-bl8Cze9pLpHBtBidOhghuQgqRrVL4kFgWRuE4_jyYj8iShs/s1600/IMG_2621.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj18a9_UtoZJP51jWDMmmDNifd3tm0K5OwUIYPuwFLlBI4jn-zT4Clz4c0mcvoc1yOIOMISc6jxcm_RbgoOYz6XA328VMn-bl8Cze9pLpHBtBidOhghuQgqRrVL4kFgWRuE4_jyYj8iShs/s640/IMG_2621.JPG" width="640" /></a></div>
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In addition to the TV, I made a huge whiteboard desk for working out psets and sketching up ideas while building. Ever since FIRST and FTC, I've placed an emphasis on documenting my sketches. In order to preserve all the sketches and design doodles that happen on the whiteboard, I'm making a <a href="http://kriste11er.blogspot.com/2013/10/raspberry-pi-time-lapse-doodling.html" target="_blank">time-lapse set up</a> with a Raspberry Pi and Pi Cam. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhTU68nIXQQhi6_KrG1YCIp9jR8baZv2_afYn_NPUZd8X_CdoeZ6AuvQYI9ZOmEI8TrT0aAk0HQAma2OJxKwD-pcSQURZlSdhZMUA31O-hVIpwjfkeB9uegaucHJW5pjEK7avuAXOtvcjg/s1600/IMG_2619.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhTU68nIXQQhi6_KrG1YCIp9jR8baZv2_afYn_NPUZd8X_CdoeZ6AuvQYI9ZOmEI8TrT0aAk0HQAma2OJxKwD-pcSQURZlSdhZMUA31O-hVIpwjfkeB9uegaucHJW5pjEK7avuAXOtvcjg/s640/IMG_2619.JPG" width="640" /></a></div>
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The TV replaced the <a href="http://kriste11er.blogspot.com/2013/02/pull-up-bar.html" target="_blank">pull-up bar</a> - brings a whole new meaning to "couch potato".Jaguar Kristellerhttp://www.blogger.com/profile/08428337775851273522noreply@blogger.com4tag:blogger.com,1999:blog-2823741957408378785.post-76100220604134862782013-09-02T12:31:00.002-04:002013-09-02T12:34:18.134-04:00Krepes: A New Type of Billiards GameRaku Watari and I used to play a lot of <a href="http://departments.weber.edu/wildcatlanes/billiard_rules.htm" target="_blank">Billiards</a> and <a href="http://departments.weber.edu/wildcatlanes/billiards/rules/CUTTHROAT.htm" target="_blank">Cut-Throat</a> at ADPhi when we were room-mates freshman year. We would try improving our techniques by hitting with spin and trying to predict where the ball would end up to be in line for the second shot. After awhile, we got tired of the same game and decided to "invent" a new one. We present Krepes:<br />
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<b>KREPES:</b><br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRd_QbTOu36Eum3E2FA56KYH7zHY-WSyiTxYObWZxlERLyeXyLEw6UD-__W45pojh5JXeuMvU-ixnxRC8UYteU7T9pZpb0p3vwVgf4eTgvih9lmZ-zMSDtoaPMGVJ916AYBp7gCnurEqI/s1600/2013-09-01+23.14.29.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRd_QbTOu36Eum3E2FA56KYH7zHY-WSyiTxYObWZxlERLyeXyLEw6UD-__W45pojh5JXeuMvU-ixnxRC8UYteU7T9pZpb0p3vwVgf4eTgvih9lmZ-zMSDtoaPMGVJ916AYBp7gCnurEqI/s640/2013-09-01+23.14.29.jpg" width="640" /></a></div>
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Why Krepes, you ask? Because we were eating Infinite Crepes at one of ADPhi's Rush events while we thought it up (and also, because it has nothing to do with the game--similar to Puzzles). </div>
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<b>Summary:</b></div>
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The game of Krepes can be played with any number of people, but 2-5 players is preferred. There is no foul for hitting a stripe or a solid directly with the cue ball (with exceptions for the 8-ball). There are two ways to hit the 8-ball and win Krepes. First, a player can use any striped ball to hit the 8-ball in a pocket--a combination shot. Second, a player can hit the 8-ball directly into a pocket IFF all the solid balls are off the table. The solid balls must be hit in order--similar to a game of <i>Nine Ball</i>. A player can pocket a striped ball to continue his/her turn, but decreases his/her chance at winning instantaneously by hitting the 8-ball in with a striped ball. This encourages strategy and multiple possible shots. If a player hits a solid ball in order, it increases his/her chances to hit the 8-ball in successfully, but does the same for his/her opponent. If all the striped balls are gone, the only way to win is to first go through the solid balls. </div>
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<b>Rules:</b></div>
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<li>The cue ball can hit any ball legally (with exceptions for the 8-ball). </li>
<li>A player wins by pocketing the 8-ball. </li>
<li>A player can pocket the 8-ball by first transferring the kinetic energy of the cue ball through a striped ball. </li>
<li>A player can pocket the 8-ball by hitting it with the cue ball directly, iff there are no solid balls on the table. </li>
<li>All solid balls must be hit in order (1-7). Pocketing a solid ball out of order may result in a foul. </li>
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<b>Fouls: Resulting in Loss of Turn</b></div>
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<li>Player hits solid ball of correct order and pockets a solid ball of incorrect order.</li>
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<b>Fouls: Resulting in a Scratch</b></div>
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<li>Player pockets a solid ball of incorrect order. </li>
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<b>Placing the Cue Ball after a Scratch:</b></div>
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A player, who follows after the previous player scratched, can place the cue ball anywhere on the table. However, he/she cannot pocket the 8-ball with a striped ball to win with his/her chosen cue ball position. </div>
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The <a href="http://departments.weber.edu/wildcatlanes/billiards/rules/general_rules.htm" target="_blank">General Rules of Pocket Billiards</a> apply except when directly contradicted by these rules. If you have any suggestions or ideas for improving the rules, please comment below. Enjoy!</div>
Jaguar Kristellerhttp://www.blogger.com/profile/08428337775851273522noreply@blogger.com0tag:blogger.com,1999:blog-2823741957408378785.post-24915052006816349152013-08-01T01:29:00.002-04:002013-08-01T02:42:13.639-04:00Electric Starter System Troubleshooting Part 1: Learning How to Drain Engine Oil Among Other ThingsI've been reading through the manual to troubleshoot why the starter switch might be causing the relay to go nuts. The <a href="https://dl.dropboxusercontent.com/u/58105293/ZX600RC1.pdf" target="_blank">ZX600RC1</a> manual referred to a <a href="https://www.dropbox.com/s/msus3cjxpehc8f2/1986-1989%20ZX600%20A-C%20series%20base%20manual.pdf" target="_blank">Base Manual</a> for going through the starter motor removal in detail (which thankfully was updated on this <a href="http://zx6r.com/service-manuals/46343-service-manual-zx600r-c-series.html" target="_blank">forum</a> 12 days ago).<br />
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After reading through the base manual, I found some possible scenarios which may be causing the symptoms it's having. A winding on the starter motor might be open (having infinite resistance) which would make it very difficult for the current to make the starter motor turn. Also, if there's a short between the commutator and the shaft, that would indicate that the armature has a short and would cause weird things to happen to the starter circuit relay. (The starter circuit relay is different than the starter relay, because it's behind the starter lockout switch. The starter lockout switch ensures that the vehicle is in neutral and the clutch is engaged - the clutch handle is out - in order to prevent the bike from being started in gear. The starter relay is what directly controls current to the starter motor).<br />
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This picture will help explain:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZxCXuqFIcUuJLVe8GEZIcpPIzOQTHPAOio_FCTE4Z1QCRjnk2iCRxT81QtblI6GcZskCP_pRn_WkinvJ3-sFnX7dhyCXvsR8fP4pUNCizT-uUXSjSuWlzKLGZOv2S6HASgf7zmkpPa5E/s1600/electric_starter_circuit.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZxCXuqFIcUuJLVe8GEZIcpPIzOQTHPAOio_FCTE4Z1QCRjnk2iCRxT81QtblI6GcZskCP_pRn_WkinvJ3-sFnX7dhyCXvsR8fP4pUNCizT-uUXSjSuWlzKLGZOv2S6HASgf7zmkpPa5E/s640/electric_starter_circuit.jpg" width="640" /></a></div>
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The recommended fix for these problems is replacing the whole starter motor (mostly because if these problems occur, the motor is old and should be replaced anyway). Dash said he has the same bike sitting in his yard, and offered to scrounge it's starter motor. Hopefully that's the problem and I can replace the starter motor with Dash's motor.<br />
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Now that it's 1:25 AM (morning of July 31, 2013), it would be ridiculous to remove the motor tonight. I will tackle this problem tomorrow.<br />
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First I tested the relay with a multimeter before ripping apart the starter motor.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHVzYEk25nNqEgujz5sessQhxg6Y6_zgZN9GbVTs0GdhoWqJOLskadzUSTIIhA72t_c5y0JQxVVtYT3T-aR9C-olnEEyi6XS9VzV4dpWm-ickjZnC9Gf80-OwcHdlQ-hUvdgIAYley0Qg/s1600/2013-07-31+21.25.13.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHVzYEk25nNqEgujz5sessQhxg6Y6_zgZN9GbVTs0GdhoWqJOLskadzUSTIIhA72t_c5y0JQxVVtYT3T-aR9C-olnEEyi6XS9VzV4dpWm-ickjZnC9Gf80-OwcHdlQ-hUvdgIAYley0Qg/s640/2013-07-31+21.25.13.jpg" width="478" /></a></div>
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8s7i-hqdbZwxAUUHl3noF1wRT3vg2FIwzuE5s9B6xmi4Ui6CqGw2ksSJgu3altSA3DqPCuhuGgseKN0KCXsyQgV-0kJ0BGG_-PU19iWHy78UHNCg2-DP4oKciupp-yRUCY3t6VGKYM7M/s1600/2013-07-31+21.25.22.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8s7i-hqdbZwxAUUHl3noF1wRT3vg2FIwzuE5s9B6xmi4Ui6CqGw2ksSJgu3altSA3DqPCuhuGgseKN0KCXsyQgV-0kJ0BGG_-PU19iWHy78UHNCg2-DP4oKciupp-yRUCY3t6VGKYM7M/s640/2013-07-31+21.25.22.jpg" width="640" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Starter Relay</td></tr>
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I disconnected the big battery and motor leads from the relay.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjF8kMGgyUAE2UtxWUgrZo0F2RpAHqYQ-k3EgYMLG6LhyJRtWTQasaeOkvsp5-QNuomz7LrI5CzDwAl6NcGXg7fzITzVl4YasCXzuLPdSBDl84lWJS3eqmOp6oIQ3Rk9xP9kGolQF0sECo/s1600/2013-07-31+21.51.37.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjF8kMGgyUAE2UtxWUgrZo0F2RpAHqYQ-k3EgYMLG6LhyJRtWTQasaeOkvsp5-QNuomz7LrI5CzDwAl6NcGXg7fzITzVl4YasCXzuLPdSBDl84lWJS3eqmOp6oIQ3Rk9xP9kGolQF0sECo/s640/2013-07-31+21.51.37.jpg" width="640" /></a></div>
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As instructed by the base manual, I measured the resistance across the battery and motor leads with them disconnected. If the relay clicked and the multimeter read 0 ohms, then it would be in good shape. However, the relay didn't click at all, and it didn't read 0 ohms. I got approximately 1 Mega ohm until I realized that was the electrical resistance of my body (from left hand to right hand). So, no resistance reading and no click; the manual says the relay is dead. It <strike>may be right</strike> it's probably right, but I still think the starter motor is at fault. I'll try another test that bypasses the relay to isolate the starter motor.<br />
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Conclusion, starter relay most likely needs replacing.<br />
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The relay is there to make all the switches regulate when the starter motor gets current. So I just bypassed the relay and all the logic with the Engine Stop Switch, Ignition Switch, Neutral Switch, and the Starter button. To bypass the relay, I just shorted the Battery lead (B) and the Motor lead (M) together. This should supply current to the starter motor and make it spin; there shouldn't be any sparks because it's basically just wiring up a motor to a battery.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhALm-tdcUT0ATaT0X77yrNJa-ZUw8SfrMy-RIoCo-fgvEetrHctBJ7ZMv6GzE_x307G8fLA6-d6gTJhCJC_tezQbugWdWwnokIrfJy9afrsQVX7s8Z_yRyl_h21cUVjWz1yljGPozEwv8/s1600/2013-07-31+21.51.54.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhALm-tdcUT0ATaT0X77yrNJa-ZUw8SfrMy-RIoCo-fgvEetrHctBJ7ZMv6GzE_x307G8fLA6-d6gTJhCJC_tezQbugWdWwnokIrfJy9afrsQVX7s8Z_yRyl_h21cUVjWz1yljGPozEwv8/s640/2013-07-31+21.51.54.jpg" width="640" /></a></div>
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The result: The battery and motor leads sparked when I first touched them. This makes me think the starter motor is shorting inside itself somewhere which would cause such a big spark where it shouldn't have.<br />
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The black smudge on the right nut resulted from the spark (basically shorting a 12V lead acid battery).<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhOLl0n-SHjXWbTFFi7t4i0aYRcNyykYhoNoo-q4-MfvbZACMoLDiApGKezyMq7DFm2ceY4DrLeo_htO7QXE1M-6o1qFBGbGx2qNysWtVP7bCn4DfUh5fEYBBwm2LCi6cpiBxrH6lXc7Io/s1600/2013-07-31+22.08.49.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhOLl0n-SHjXWbTFFi7t4i0aYRcNyykYhoNoo-q4-MfvbZACMoLDiApGKezyMq7DFm2ceY4DrLeo_htO7QXE1M-6o1qFBGbGx2qNysWtVP7bCn4DfUh5fEYBBwm2LCi6cpiBxrH6lXc7Io/s640/2013-07-31+22.08.49.jpg" width="640" /></a></div>
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After shorting them for more than a split second the starter motor sounded as if it were trying to turn but couldn't. It is definitely shorting somewhere inside the motor, but maybe only on one winding (which would explain why it sometimes makes the relay unhappy and sometimes spins). The problem may be a combination of both the starter motor and the relay. But this test confirms that I need to disassemble the starter motor and see what's inside. Time to get a little messy.<br />
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The starter motor is hidden behind an oil line and a coolant hose. I wonder why they designed it this way!? It sure would've been nice to be able to remove the starter motor without draining the coolant system and engine oil.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjc7w-1YrjlcnnHSQ4tJuxi0B7Rs84l8CSg5D6IYJHZ9XHc1LWhF6wDErvDcVFKTleoMmV3WfNsq4F3n30N5gyFOHuWqRBVtBI0SovjB1fdG3PK7N8OEuaKaZJBPZ1xcRuWnCgNlTS4ols/s1600/labeled_starter_motor.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjc7w-1YrjlcnnHSQ4tJuxi0B7Rs84l8CSg5D6IYJHZ9XHc1LWhF6wDErvDcVFKTleoMmV3WfNsq4F3n30N5gyFOHuWqRBVtBI0SovjB1fdG3PK7N8OEuaKaZJBPZ1xcRuWnCgNlTS4ols/s640/labeled_starter_motor.jpg" width="640" /></a></div>
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Oh, the engine is full of oil, and if I removed the starter motor, all the oil would drain out the starter motor hole. But why the coolant system? Maybe it needs to be replenished more often than fixing the starter motor. So, if the starter motor breaks, then it's probably a good time to cycle the coolant system. Maybe it's a good design after all...<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-NMVAdB90DiqZD-24ELALV5StqgowN7UQfrrByTZymAUli71V8k4UrWL6a4qISlcCBFpJvUvj9dsJzvwjKFSMrcbaumrP-I2Nrzu1Pc_Wpm2VwsZWTqicfVKnIs8cWtCDQBtbCDaOPTQ/s1600/2013-07-31+22.17.13.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-NMVAdB90DiqZD-24ELALV5StqgowN7UQfrrByTZymAUli71V8k4UrWL6a4qISlcCBFpJvUvj9dsJzvwjKFSMrcbaumrP-I2Nrzu1Pc_Wpm2VwsZWTqicfVKnIs8cWtCDQBtbCDaOPTQ/s640/2013-07-31+22.17.13.jpg" width="640" /></a></div>
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<b>Draining engine oil: </b>It's pretty simple actually. Unscrew the engine oil drain plug and drain it into a pan. Finding a grungy pan was the hardest part. This <a href="http://www.instructables.com/id/Motorcycle-oil-change/step9/Enjoy/" target="_blank">instructable</a> explains how to drain oil from a motorcycle engine. Important note: If the engine is hot (i.e. the oil is also hot), then the oil drains much better than if it were cold. So, run the engine for a little while before draining the oil.<br />
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Ever wonder what oil labels like 10W40, 10W50, or 20W40 mean? The different numbers basically indicate how viscous the oil is and how "<a href="http://www.machinerylubrication.com/Read/171/oil-can" target="_blank">pumpable</a>" it is at certain temperatures. Certain systems require different types of oil (e.g. smaller engines that have smaller hoses would need a less viscous oil to ensure that it flows well).<br />
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<b>Draining the Coolant System: </b>Note to self... Make sure to check the coolant from the reservoir tank and not the radiator cap. The radiator cap opens up the air tight coolant system and lets air in. Therefore, by simply opening the radiator cap you're dooming yourself to bleeding the coolant system of air. Air in the coolant system isn't super bad, but it lowers the efficiency of your cooling system and its ability to take heat away from the engine.<br />
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The coolant is NOT just water. It's about a 50/50 mix with a green liquid called <a href="http://en.wikipedia.org/wiki/Ethylene_glycol#Antifreeze" target="_blank">ethylene glycol</a>. It's basically the sweet pink antifreeze that you would put in the water system of a motor-home to keep the pipes from freezing in the winter - hence "antifreeze".<br />
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Unlike draining engine oil, it's best to drain the coolant long after the engine has run when it's at room temperature.<br />
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<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxxL34u3vVLTnVtzKUv4T77emiWo_iK-saox68tp-7acq__HcvwPIKxLLFzLVJHhbAsQwyWQWAU-ITtR95rBG4YsRZdHiDN_irKrhCVQC82P5IUzDug-ihQ4DQATQkHmti2lTySuJLhPg/s1600/2013-08-01+00.41.45.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjxxL34u3vVLTnVtzKUv4T77emiWo_iK-saox68tp-7acq__HcvwPIKxLLFzLVJHhbAsQwyWQWAU-ITtR95rBG4YsRZdHiDN_irKrhCVQC82P5IUzDug-ihQ4DQATQkHmti2lTySuJLhPg/s640/2013-08-01+00.41.45.jpg" width="640" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Ran over to the Sunoco gas station near MITERS</td></tr>
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Coolant is a mixture of water and ethylene glycol antifreeze; there aren't any variations like with oil. So anything with ethylene glycol in it works fine. However, one thing to keep in mind, motorcycle coolant is not the same thing as coolant used in cars! So don't even think about using the same stuff for both vehicles. You can buy stuff premixed, but your half of what your paying for is slightly overpriced water. You could also mix it yourself, but be sure to use distilled water. The minerals and ions in tap water can cause corrosion to internal engine components, which isn't very good. I'm sure you can use tap water (as some people do and their engines run "fine") but it limits the life of the engine and <strike>may</strike> will cause more problems in the long run.<br />
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Over the weekend, I'm traveling up to Wilkes-Barre, Pennsylvania to pick up the Kawasaki KLR650 that my Dad rode down when I was heading to school. I don't want the motorcycle to sit without oil over the weekend, so I will drain all its guts when I get back. (Though, it would have been nice to figure out what the problem with the starter motor is and buy replacement parts if need be so they can be shipping while I'm away).<br />
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<b>Next things to do:</b><br />
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<ul>
<li>Drain engine oil and coolant. </li>
<li>Remove the starter oil and check its bearings, coils, brushes, can for anything that might be preventing it to spin. </li>
<li>Fix the problem (order any necessary components) and replace oil and coolant fluids. </li>
<li>Tighten up loose bolts around the frame (seat arm and shifting lever). </li>
<li>Long term: Carbon fiber fairings! :)</li>
</ul>
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><br />
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRedzjs7ZKp6fY94J-YNxq8WkplvB-jQfMiqMYp0FCEciMel_4oZZXwZANicQjiJ5VHa3-uEzRV-Dtw1grnJU3TpFX6bCMAwmwFDDvrcyjJAza2Xk18DdZq95JczMkb4Iw43GkYEzSqwo/s1600/2013-07-31+23.07.31.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRedzjs7ZKp6fY94J-YNxq8WkplvB-jQfMiqMYp0FCEciMel_4oZZXwZANicQjiJ5VHa3-uEzRV-Dtw1grnJU3TpFX6bCMAwmwFDDvrcyjJAza2Xk18DdZq95JczMkb4Iw43GkYEzSqwo/s640/2013-07-31+23.07.31.jpg" width="640" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Ironic</td></tr>
</tbody></table>
Mikuvan and *.mtrcl. Vehicles destined to remain gas guzzlers.Jaguar Kristellerhttp://www.blogger.com/profile/08428337775851273522noreply@blogger.com0tag:blogger.com,1999:blog-2823741957408378785.post-43015060699201555522013-07-30T02:25:00.007-04:002013-07-31T00:10:15.909-04:00Motorbycle: A Bigger Electric Vehicle... Or So I Thought<div style="text-align: center;">
<img border="0" height="478" src="http://4.bp.blogspot.com/-QIvlv9YGCXU/UfX01y1S3jI/AAAAAAAACTQ/zPbCYsqVKRo/s640/IMG_2434.JPG" width="640" /></div>
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After the Electric Orbit Wheels and the extremely fun nights/early mornings in the Stata Parking Garage with <a href="http://build-its.blogspot.com/" target="_blank">Ben's</a> <a href="http://www.instructables.com/id/Electric-Tricycle/" target="_blank">Trike</a>, I started thinking about a bigger, faster electric vehicle. The Electric Orbit Wheels are great for short commutes around MIT, but not for midnight garaging. </div>
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I started playing with the idea of returning to my childhood and making a small motorcycle (not a pocket bike, but a small motorcycle similar to Mars's). (I also wanted to make my own Continuously Variable Transmission (CVT) to help with drag racing in the garage.) I've actually been riding motorcycles for most of my life, I've just never taken one apart or built my own. It's time for that to change.</div>
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<a href="http://3.bp.blogspot.com/-la6OwgpFicI/UfXsaAz-0UI/AAAAAAAAB_0/1R9vP-l7rww/s1600/SDC10399.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="http://3.bp.blogspot.com/-la6OwgpFicI/UfXsaAz-0UI/AAAAAAAAB_0/1R9vP-l7rww/s640/SDC10399.JPG" width="640" /></a></div>
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<span style="-webkit-composition-fill-color: rgba(175, 192, 227, 0.230469); -webkit-composition-frame-color: rgba(77, 128, 180, 0.230469); -webkit-tap-highlight-color: rgba(26, 26, 26, 0.292969);">I don't remember this story from my point of view, but this is similar to how my Dad tells it. </span></div>
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When I was two years old, my Dad bought a small 50cc Yamaha motorcycle and put it in his old <a href="http://en.wikipedia.org/wiki/File:LandRoverIIALWB.jpg" target="_blank">1966 LandRover Series II A</a> as a way to hide my birthday present. Somehow I found out and kept telling my Mom, "There's a motorbycle in the police car!". She had no idea what I meant until <span style="-webkit-composition-fill-color: rgba(175, 192, 227, 0.230469); -webkit-composition-frame-color: rgba(77, 128, 180, 0.230469); -webkit-tap-highlight-color: rgba(26, 26, 26, 0.292969);">my third birthday.</span><span style="-webkit-composition-fill-color: rgba(175, 192, 227, 0.230469); -webkit-composition-frame-color: rgba(77, 128, 180, 0.230469); -webkit-tap-highlight-color: rgba(26, 26, 26, 0.292969);"> </span></div>
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<span style="-webkit-composition-fill-color: rgba(175, 192, 227, 0.230469); -webkit-composition-frame-color: rgba(77, 128, 180, 0.230469); -webkit-tap-highlight-color: rgba(26, 26, 26, 0.292969);"><br />
</span></div>
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<span style="-webkit-composition-fill-color: rgba(175, 192, 227, 0.230469); -webkit-composition-frame-color: rgba(77, 128, 180, 0.230469); -webkit-tap-highlight-color: rgba(26, 26, 26, 0.292969);">I first learned how to ride a motorcycle with my dad walking behind holding the back. Ever since, we've been riding as a family out on trails in the middle-of-no-where on dirt bikes and four-wheelers.</span></div>
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Here's a few of our trips out to Old Murphy Dome Road and Moose Mountain (a ski resort in the winter):<br />
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<a href="http://2.bp.blogspot.com/-Yqdjfir7U7Y/UfXsaMNHEkI/AAAAAAAAB_w/15zVzdqMZkY/s1600/SDC10374.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="http://2.bp.blogspot.com/-Yqdjfir7U7Y/UfXsaMNHEkI/AAAAAAAAB_w/15zVzdqMZkY/s640/SDC10374.JPG" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNxP4yoPvKcLrA7rDqK6Hje5bcyMwUhJHU72Xi3xOV6B4_MDXM_oLvq4DM0WFvI1dNCYRQD6JiejjFl-1n_WSy0yL21UNiLzJhyphenhyphen9vnMotOYZnT3It46Yu2ckUAxFbpn3XSkblEBF_f9iY/s1600/SDC10389.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNxP4yoPvKcLrA7rDqK6Hje5bcyMwUhJHU72Xi3xOV6B4_MDXM_oLvq4DM0WFvI1dNCYRQD6JiejjFl-1n_WSy0yL21UNiLzJhyphenhyphen9vnMotOYZnT3It46Yu2ckUAxFbpn3XSkblEBF_f9iY/s640/SDC10389.JPG" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvtteYCbQzhpvRcwmYJV9NwVsAXtKVWzQ-19DY4iuJUE2VbDHV9vXpzDVx7lxDnpI0ztLG2YuxMEh1-7EKysvK-g72sDEofdc0d2fvO72-i8wpnx3_xjGkqt5RMj9C7Uncy3cgRY9xz5Y/s1600/2013-07-01+22.29.54.jpg" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvtteYCbQzhpvRcwmYJV9NwVsAXtKVWzQ-19DY4iuJUE2VbDHV9vXpzDVx7lxDnpI0ztLG2YuxMEh1-7EKysvK-g72sDEofdc0d2fvO72-i8wpnx3_xjGkqt5RMj9C7Uncy3cgRY9xz5Y/s640/2013-07-01+22.29.54.jpg" width="640" /></a></div>
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="http://1.bp.blogspot.com/-l7LMyxCfHUY/UfVHhSANHEI/AAAAAAAAB5M/tspM2YzTb08/s1600/2013-07-01+22.30.10.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" height="478" src="http://1.bp.blogspot.com/-l7LMyxCfHUY/UfVHhSANHEI/AAAAAAAAB5M/tspM2YzTb08/s640/2013-07-01+22.30.10.jpg" width="640" /></a></td></tr>
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</tbody></table>
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My Dad would ride a slightly bigger motorcycle, so when I grew up, I would use his and upgrade to a bigger bike. After the little Yamaha, I progressed to a <a href="http://www.smartcarguide.com/listimg/img1_0413/28/img_10870302_00.jpg" target="_blank">110cc Kawasaki</a>. After that, a <a href="http://vintagemx.com.au/wp-content/gallery/yamaha-yz125/2007_yz125.jpg" target="_blank">125cc Yamaha</a> (in the picture above). </div>
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh35FTVwRJ3grybz1H_hWY3_cwPOJvb3NJo6YrhzTehpimSI57lfpm6TpklqCO0AGLSiR0hE1lvL7TPBvqD1A-E7j7YWxmHRO5vO1PKdq_3uqSKtuhAagRMDTm_k3C6O-RU9gyjqVpp3dw/s640/2013-07-01+22.29.51.jpg" style="margin-left: auto; margin-right: auto;" width="640" /></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Moose Mountain Ski Trails</td></tr>
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<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="http://1.bp.blogspot.com/-Vl0UT3ZqIZA/UfVHh92280I/AAAAAAAAB5c/eqHscrf9laM/s1600/2013-07-01+22.49.41.jpg" style="margin-left: auto; margin-right: auto;"><img border="0" height="478" src="http://1.bp.blogspot.com/-Vl0UT3ZqIZA/UfVHh92280I/AAAAAAAAB5c/eqHscrf9laM/s640/2013-07-01+22.49.41.jpg" width="640" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Forest Fire Dead Tree Zone</td></tr>
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We actually couldn't ride on our preferred trails one year, because the fire fighters were using it to fight the fires.<br />
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When I went back this past summer to film the <a href="http://kriste11er.blogspot.com/2013/06/earth-in-foreground-flying-into.html" target="_blank">24-hour sunlight</a> up above the Arctic Circle, I tried out my Dad's new motorcycle.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjoS-fQy1-LstFC-pVgyssS-hYavxzguc1NOeCBhq9B5U9sXKFn5gyjyfm2SSwSiDM-53repOKqZXI8P-UhifJPDE28dnbROmxuXLpP79UL1nvJiTI8VwPeztuNXqzgYHcE3q86pLnSqgc/s1600/IMG515.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjoS-fQy1-LstFC-pVgyssS-hYavxzguc1NOeCBhq9B5U9sXKFn5gyjyfm2SSwSiDM-53repOKqZXI8P-UhifJPDE28dnbROmxuXLpP79UL1nvJiTI8VwPeztuNXqzgYHcE3q86pLnSqgc/s640/IMG515.jpg" width="640" /></a></div>
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Riding that bike was SO much fun!!! I felt so powerful! It's a four cylinder and is super quite. I can be cruising at 70mph and then still accelerate like I was going 20mph! It felt great. And I definitely want a sport bike now...</div>
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After seeing Bailey's $50 bike with a frame, wheels, brakes, and everything, I decided it would be much more cost effective to buy a bike and turn it into an electric motorcycle. It would have been fun to make a frame, but it would have been twice as much if not more. </div>
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So I began craiglist motorcycle hunting. I searched for motorcycles between $2 and $500 to weed out the super expensive new sports bikes. I also had the picture option selected and then scrolled through the various motorcycles in grid view. </div>
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After about a month of searching and a few failed attempts, I found a red Kawasaki Ninja 600R for $225. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1cGHHrXj36kVc-WIInAxi47QZ4eDMivX1pJLRR6dwjbqFrAB_oIVqyKU-nXarqKMJISKK-tVUo8dyXN5v5CaxHJgMY-hppZJO_yY4ByHcapx1mTmxWLHxTxGOuUdTweCi99sl76HhKOw/s1600/Screenshot+from+2013-07-28+23:49:35.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="360" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1cGHHrXj36kVc-WIInAxi47QZ4eDMivX1pJLRR6dwjbqFrAB_oIVqyKU-nXarqKMJISKK-tVUo8dyXN5v5CaxHJgMY-hppZJO_yY4ByHcapx1mTmxWLHxTxGOuUdTweCi99sl76HhKOw/s640/Screenshot+from+2013-07-28+23:49:35.png" width="640" /></a></div>
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The guy offered to deliver it for $25, and before I knew it the bike arrived at MITERS. <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOZtlHHgO6KlUlyqF95E_o70BFc6VhgvjmZhzhWzFBBRNw6rPDuZJYUu_weClgSkN1oDe6cWAUVsJ-rrLRDJrmV7CMqBlGKSxF0T8K6o1LOqbGE45kytEyw9haMrlMQ2PR43uGduKolCI/s1600/IMG_2376.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjOZtlHHgO6KlUlyqF95E_o70BFc6VhgvjmZhzhWzFBBRNw6rPDuZJYUu_weClgSkN1oDe6cWAUVsJ-rrLRDJrmV7CMqBlGKSxF0T8K6o1LOqbGE45kytEyw9haMrlMQ2PR43uGduKolCI/s640/IMG_2376.JPG" width="640" /></a></div>
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It has 15,177 miles, which is pretty far for an old 1989 bike. It would have been fine for an electric bike used in parking garages, but for going long distances it only has about another 5,000 miles.<br />
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<a href="http://2.bp.blogspot.com/-TAECbQpGu5w/UfX0nrEQoxI/AAAAAAAACME/uRjTkdThKx0/s1600/IMG_2377.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://2.bp.blogspot.com/-TAECbQpGu5w/UfX0nrEQoxI/AAAAAAAACME/uRjTkdThKx0/s640/IMG_2377.JPG" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_ULVvqnkmFmd5ll53ehEzVnDqL8a-e7w7xX6PsYVoV6jAzLDj8GKB_QE6J7q0U2aTa4KTrY14Tfle8AvcgGYVOU2cFXGzir_2qNWQolL8murdHkHhtalzwXh4n0_rrg8sNnjQM3IFNPQ/s1600/IMG_2379.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi_ULVvqnkmFmd5ll53ehEzVnDqL8a-e7w7xX6PsYVoV6jAzLDj8GKB_QE6J7q0U2aTa4KTrY14Tfle8AvcgGYVOU2cFXGzir_2qNWQolL8murdHkHhtalzwXh4n0_rrg8sNnjQM3IFNPQ/s640/IMG_2379.JPG" width="640" /></a></div>
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<a href="http://4.bp.blogspot.com/-Obx4MU0kEiQ/UfX0oZfyamI/AAAAAAAACMs/wPCE7wvoFj4/s1600/IMG_2380.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://4.bp.blogspot.com/-Obx4MU0kEiQ/UfX0oZfyamI/AAAAAAAACMs/wPCE7wvoFj4/s640/IMG_2380.JPG" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEguBGs7bucZkjbHioJ4qHW18eXuEVKdZGYk9_ah91klv3-o2XOdya1woztZq9si5In5ZsmZjdTUA8YPkBy3j5DnP7-A5xUZ35oc0zG9KhPGCwHS_XVnDQ5KIc1bCRvcXBClNcyBuEWm7qM/s1600/IMG_2381.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEguBGs7bucZkjbHioJ4qHW18eXuEVKdZGYk9_ah91klv3-o2XOdya1woztZq9si5In5ZsmZjdTUA8YPkBy3j5DnP7-A5xUZ35oc0zG9KhPGCwHS_XVnDQ5KIc1bCRvcXBClNcyBuEWm7qM/s640/IMG_2381.JPG" width="478" /></a></div>
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I got a pair of matching keys, a broken key, a bill of sale that the seller wrote with the previous owner when he was buying the bike, and a registration that expired in March of 2013.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDKowUGD3fQaZmlOEWlS7XwnvEH73lP0DHObwrTO76_2h5dhbxUUh6dx8147xCMFxA522bWzBLxOTpLCGFF-HadlTG6YCNl9K4O667zxZYxXSHKLmbbU0WTsl4q-jMKh0kxJCF5ri9Zsc/s1600/IMG_2391.JPG"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDKowUGD3fQaZmlOEWlS7XwnvEH73lP0DHObwrTO76_2h5dhbxUUh6dx8147xCMFxA522bWzBLxOTpLCGFF-HadlTG6YCNl9K4O667zxZYxXSHKLmbbU0WTsl4q-jMKh0kxJCF5ri9Zsc/s320/IMG_2391.JPG" width="640" /></a></div>
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The keys ARE the same and they do go to the ignition, fuel tank, and seat which makes me think this bike has a verified history of ownership. That might make it a little easier to get a title. I bought it without a title thinking I wouldn't ride it on the road and just convert it to electric. But now that its running, I kind of want a title. <br />
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Time to take off the <strike>covers</strike> fairings and see what's underneath.<br />
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<a href="http://4.bp.blogspot.com/-Z7_5l3TrP3M/UfX0pJMfXyI/AAAAAAAACM0/dHaWE-mGBBA/s1600/IMG_2383.JPG" imageanchor="1"><img border="0" height="478" src="http://4.bp.blogspot.com/-Z7_5l3TrP3M/UfX0pJMfXyI/AAAAAAAACM0/dHaWE-mGBBA/s320/IMG_2383.JPG" width="640" /></a></div>
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While I was taking it apart, I was trying to find clues that might prove that this bike had verified owners. The matching key was a good clue, but there may be more. I was also looking for what the previous owner had done to try and make it work (to learn from it and to help problem solve). <br />
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<a href="http://3.bp.blogspot.com/-AfjdF2_CaEo/UfX0rT9HG1I/AAAAAAAACOk/eReu_2JC98Q/s1600/IMG_2392.JPG" imageanchor="1"><img border="0" height="478" src="http://3.bp.blogspot.com/-AfjdF2_CaEo/UfX0rT9HG1I/AAAAAAAACOk/eReu_2JC98Q/s320/IMG_2392.JPG" width="640" /></a></div>
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I found a bare wire. Along with a connector that wasn't even connected. <br />
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<a href="http://4.bp.blogspot.com/-vNSuUPWUOGg/UfX0zJ5VzwI/AAAAAAAACR4/IipOmofaMaw/s1600/IMG_2423.JPG"><img border="0" height="478" src="http://4.bp.blogspot.com/-vNSuUPWUOGg/UfX0zJ5VzwI/AAAAAAAACR4/IipOmofaMaw/s320/IMG_2423.JPG" width="640" /></a></div>
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It looks like it goes to a 12V "Regulator Rectifier" which is used to charge the battery from the engine. So, I plugged it back in.<br />
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The back light and back blinkers had a big white connector and crimps that could be easily disconnected. These were connected to the back fairing, and came off when I took the fairings off. <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1VQ0O9M0t6SQBExrVupgZqjN2UIuFAJczsmzZmQ7DFBhFbl9YkgO5BalvHWC16ntYKOEL4HN7cUWZPONR1EQ-t3_LyuJEZpdzZFaFOdIjalBLwVIwsFnZoD4UgpZSFr-_Jsd0ZSnOPwQ/s1600/IMG_2393.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1VQ0O9M0t6SQBExrVupgZqjN2UIuFAJczsmzZmQ7DFBhFbl9YkgO5BalvHWC16ntYKOEL4HN7cUWZPONR1EQ-t3_LyuJEZpdzZFaFOdIjalBLwVIwsFnZoD4UgpZSFr-_Jsd0ZSnOPwQ/s640/IMG_2393.JPG" width="640" /></a></div>
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<a href="http://1.bp.blogspot.com/--mSmlNw8t60/UfX0r7bk5uI/AAAAAAAACOE/ymyoUm-_Fuo/s1600/IMG_2394.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/--mSmlNw8t60/UfX0r7bk5uI/AAAAAAAACOE/ymyoUm-_Fuo/s640/IMG_2394.JPG" width="640" /></a></div>
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There was some evidence that the bike had been laid on both sides. It didn't look to scuffed, which would indicate that it probably just fell over at a stand still.<br />
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<a href="http://1.bp.blogspot.com/-z5TUEqHAEYI/UfX0tr8W-7I/AAAAAAAACO8/Q8XkthOAtbU/s1600/IMG_2401.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-z5TUEqHAEYI/UfX0tr8W-7I/AAAAAAAACO8/Q8XkthOAtbU/s640/IMG_2401.JPG" width="640" /></a></div>
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<a href="http://3.bp.blogspot.com/-FKGBJtUo1_g/UfX0uNKf9gI/AAAAAAAACPQ/_dBNnH4MngA/s1600/IMG_2403.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://3.bp.blogspot.com/-FKGBJtUo1_g/UfX0uNKf9gI/AAAAAAAACPQ/_dBNnH4MngA/s640/IMG_2403.JPG" width="640" /></a></div>
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For a 1989 bike, it's in great shape! <br />
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Wait... What? Why does that say 88???<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLBBd7SW6K49XOZew5MQvwwHE0D1SxZWwsGrCGpLu0m4wnUF59v73G6a1CnqhwphDFFO-6xuBtu3laQa8JaZn4ctALH1GdJd3_ngKZJaER1nFF7AaSHjqEiJei7Ou6EbX2fRpbyw4NFBY/s1600/IMG_2408.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLBBd7SW6K49XOZew5MQvwwHE0D1SxZWwsGrCGpLu0m4wnUF59v73G6a1CnqhwphDFFO-6xuBtu3laQa8JaZn4ctALH1GdJd3_ngKZJaER1nFF7AaSHjqEiJei7Ou6EbX2fRpbyw4NFBY/s640/IMG_2408.JPG" width="640" /></a></div>
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The registration has it registered as an 89 with a valid VIN. The fairings are probably interchangeable between 88s and 89s. (Which would also explain the different color and texture paint job from the bikes frame). </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRQijxPBW3wU8VXQMQalKtF3ytbW_nehxDBLyNeUPjIcpiDSxh7K22cBFS3Aub9Fki2F0DpOHXx1Di4SJSeHdI70kx3-qMY_cNVuwcAVzr4dLI0QXD49-Wp7AD2c_KoYks86L8WFFJJ5E/s1600/IMG_2410.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhRQijxPBW3wU8VXQMQalKtF3ytbW_nehxDBLyNeUPjIcpiDSxh7K22cBFS3Aub9Fki2F0DpOHXx1Di4SJSeHdI70kx3-qMY_cNVuwcAVzr4dLI0QXD49-Wp7AD2c_KoYks86L8WFFJJ5E/s640/IMG_2410.JPG" width="640" /> </a></div>
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The frame is a solid black color which feels and looks like a proper paint job (but again, I'm not an expert on this at this point in the game). The fairings seem like they were spray painted (or maybe they just have a different but proper paint texture). </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhfHVGpSN3kOd65EOz9XKyaHYcvMZNTY_bjBM815RTEr0WIA1gn0LQid-z1D6m4NJkQ8oW2PpmK0gDd7NPGU4_HPv0sS7sZOdjYx7Wr4Grpsce8dv_y0AfLh3Wq67rn3WggdTQwJLDjcbk/s1600/IMG_2411.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhfHVGpSN3kOd65EOz9XKyaHYcvMZNTY_bjBM815RTEr0WIA1gn0LQid-z1D6m4NJkQ8oW2PpmK0gDd7NPGU4_HPv0sS7sZOdjYx7Wr4Grpsce8dv_y0AfLh3Wq67rn3WggdTQwJLDjcbk/s640/IMG_2411.JPG" width="640" /></a></div>
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Also, I've never seen this logo before on the Internet. It didn't have the classic Ninja logo with Kawasaki to the left. The old registration does confirm that this bike was built by Kawasaki. <br />
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Maybe the fairings are just aftermarket replacement parts. <br />
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<a href="http://3.bp.blogspot.com/-kxNK_GpP5YE/UfX0tDoYQiI/AAAAAAAACPk/MEYL78ZAMfA/s1600/IMG_2399.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://3.bp.blogspot.com/-kxNK_GpP5YE/UfX0tDoYQiI/AAAAAAAACPk/MEYL78ZAMfA/s640/IMG_2399.JPG" width="640" /></a></div>
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This bike was manufactured by Kawasaki, in Japan, with Metric screws. Most of the fairing bolts were 10 mm. This might also be a clue that someone didn't just refurbish the fairings and use handy Standard bolts lying around. Metric screws are a good sign.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbW5CiZLbc3SqsSVSC4YGsTIPkvBOZ2u_Sk62z_wy6Md6dbz_GXshZFvMU8loJEhtKfGkak8kHLhv0CYRWl26wkv1VeW4pjInTC6oRz_4bmqw7rvh3-JKonJy29-y4nn36V25MlfDjDHw/s1600/IMG_2412.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbW5CiZLbc3SqsSVSC4YGsTIPkvBOZ2u_Sk62z_wy6Md6dbz_GXshZFvMU8loJEhtKfGkak8kHLhv0CYRWl26wkv1VeW4pjInTC6oRz_4bmqw7rvh3-JKonJy29-y4nn36V25MlfDjDHw/s640/IMG_2412.JPG" width="640" /></a></div>
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The front blinker assembly was cracked pretty badly; it was probably caused by dropping the bike. <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiamaCvVhEuXpIa3h0Ib_fPHSrMXnhXWnyMrBvrCGK1qDiBfVGoafIXftJY1uQtueYEUWJbcDxweYs4JRA68BeMrg3yngmGCbBEn-rm_LOYG8EmKkzMnpKNRWz5lwnAnqs5O8oM_Q_d7pY/s1600/IMG_2413.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiamaCvVhEuXpIa3h0Ib_fPHSrMXnhXWnyMrBvrCGK1qDiBfVGoafIXftJY1uQtueYEUWJbcDxweYs4JRA68BeMrg3yngmGCbBEn-rm_LOYG8EmKkzMnpKNRWz5lwnAnqs5O8oM_Q_d7pY/s640/IMG_2413.JPG" width="640" /></a></div>
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I tried to take pictures of which screws, nuts, washers, and grommets went where. They may come in handy later on, when I've completely forgotten.<br />
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This bolt was bent! Maybe a result from dropping it (though the fairing isn't scratched up)? <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhguAHwPnXovP0l-zQWcLbdNZzMKjPIZT7xDE4Y5fg25iqiHn4HiT71PLIp2pERQpXH-JftLZKSHgfjeabK-HUsHD0waJ5aMD7UzaKMxf4nvV88OXERISGrwaG7VSqXSZZI80rb3Qfo3mY/s1600/IMG_2404.JPG" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhguAHwPnXovP0l-zQWcLbdNZzMKjPIZT7xDE4Y5fg25iqiHn4HiT71PLIp2pERQpXH-JftLZKSHgfjeabK-HUsHD0waJ5aMD7UzaKMxf4nvV88OXERISGrwaG7VSqXSZZI80rb3Qfo3mY/s640/IMG_2404.JPG" width="640" /></a> </div>
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<a href="http://2.bp.blogspot.com/-9V6xuAkv6RQ/UfX0xUkaTKI/AAAAAAAACRM/JP2pfLJpSjQ/s1600/IMG_2415.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://2.bp.blogspot.com/-9V6xuAkv6RQ/UfX0xUkaTKI/AAAAAAAACRM/JP2pfLJpSjQ/s640/IMG_2415.JPG" width="640" /></a></div>
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The shifter mechanism is a little loose, but it works well for first and neutral. Though, it doesn't seem to want to go into second. Usually you can shift a gear, roll it forward, and shift again. However, it just doesn't want to shift to second. <a href="http://yameb.blogspot.com/" target="_blank">Dgonz</a> and Thomas suspected maybe the transmission gears weren't meshing (possibly because of a nasty jam). If that were the case, fixing it would mean literally disassembling the frame (because on ninjas, the frame is held together by the engine). <br />
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<a href="http://3.bp.blogspot.com/-4yzvnck77d0/UfX0xuIc69I/AAAAAAAACRI/Skxb8NynZ_Y/s1600/IMG_2416.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://3.bp.blogspot.com/-4yzvnck77d0/UfX0xuIc69I/AAAAAAAACRI/Skxb8NynZ_Y/s640/IMG_2416.JPG" width="640" /></a></div>
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This welded joint kind of scares me. I will definitely touch this up before riding around a bunch. However, MITERS is currently out of a welder. <br />
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It looks like it helps mount the braking assembly to the swing arm. Therefore, if I brake really hard and abruptly it could get ugly. <br />
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<a href="http://2.bp.blogspot.com/-dERGo_cXKy8/UfX0yDghA2I/AAAAAAAACRU/L4rkkvDv4_k/s1600/IMG_2418.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://2.bp.blogspot.com/-dERGo_cXKy8/UfX0yDghA2I/AAAAAAAACRU/L4rkkvDv4_k/s640/IMG_2418.JPG" width="640" /></a></div>
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That looks like a pipe for fluid near the rear wheel brake foot bar (pedal). Braking fluid?<br />
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<a href="http://1.bp.blogspot.com/-h5aQkC3QIv4/UfX0yZ6dhiI/AAAAAAAACRY/npWwE9hpU1Y/s1600/IMG_2419.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-h5aQkC3QIv4/UfX0yZ6dhiI/AAAAAAAACRY/npWwE9hpU1Y/s640/IMG_2419.JPG" width="640" /></a></div>
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Yep, it's brake fluid. <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgY2iI5ysEnG6r87_SLg0O17pOHrEhxzw4oS56IlhxbarrkgE4U-G1hCHHdjG7gPMRpqgLeXNxKzWrCMD8UriXZZlWuRPgXP6tnMiCq-RZCZe_tdab8TUOC8vLx23RY9h8RXy6pY-8Q_WI/s1600/IMG_2420.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgY2iI5ysEnG6r87_SLg0O17pOHrEhxzw4oS56IlhxbarrkgE4U-G1hCHHdjG7gPMRpqgLeXNxKzWrCMD8UriXZZlWuRPgXP6tnMiCq-RZCZe_tdab8TUOC8vLx23RY9h8RXy6pY-8Q_WI/s640/IMG_2420.JPG" width="640" /></a></div>
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One thing that surprised me, there was some slop when I was lifting the bike up by the back bar. Further inspection pointed towards a loose allen wrench bolt. Maybe the previous owner disassembled it and forgot to tighten everything. <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi72Y39DEf75U0rUOEeSeuSqsIMZBGa8Moz0_Rzpa8OwGapaUOlUMgpDKWA0HSqfSOpeMs4jgkggi6Nv3KRkfqWpb38J8NbQfjX7WN7DLGeLpiQAR6uJrwJwCNZwXk-0fUTdEeP4WECoFY/s1600/IMG_2426.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi72Y39DEf75U0rUOEeSeuSqsIMZBGa8Moz0_Rzpa8OwGapaUOlUMgpDKWA0HSqfSOpeMs4jgkggi6Nv3KRkfqWpb38J8NbQfjX7WN7DLGeLpiQAR6uJrwJwCNZwXk-0fUTdEeP4WECoFY/s640/IMG_2426.JPG" width="640" /></a></div>
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Partially disassembled fairings. <br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyY3ikBlhNdKVU47RI_EkFz2hxQ-XanrE1E4HhEuq70_PmFG3YKl5tEpHD9spBXaYhJD3wyEcaIEhObyhrznPIr5OeNldLSkrgLCud-tdJLgmdOlWaVN4FGmSzmoZO0S13fJ5dUnMh1Gw/s1600/IMG_2429.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyY3ikBlhNdKVU47RI_EkFz2hxQ-XanrE1E4HhEuq70_PmFG3YKl5tEpHD9spBXaYhJD3wyEcaIEhObyhrznPIr5OeNldLSkrgLCud-tdJLgmdOlWaVN4FGmSzmoZO0S13fJ5dUnMh1Gw/s640/IMG_2429.JPG" width="640" /></a></div>
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That's the horn in the lower-left corner. When all the lights and blinkers are off and disconnected, I can use the horn to test whether or not the electrical system is working. <br />
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<a href="http://1.bp.blogspot.com/-qB11eCAb2rQ/UfX01XRRTsI/AAAAAAAACS8/2AEXWAJF7Ms/s1600/IMG_2432.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-qB11eCAb2rQ/UfX01XRRTsI/AAAAAAAACS8/2AEXWAJF7Ms/s640/IMG_2432.JPG" width="640" /></a></div>
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Fairings off, and ready to debug. <br />
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<a href="http://4.bp.blogspot.com/-QIvlv9YGCXU/UfX01y1S3jI/AAAAAAAACTQ/zPbCYsqVKRo/s1600/IMG_2434.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://4.bp.blogspot.com/-QIvlv9YGCXU/UfX01y1S3jI/AAAAAAAACTQ/zPbCYsqVKRo/s640/IMG_2434.JPG" width="640" /></a></div>
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There are four exhaust pipes which indicates that it's a four cylinder engine. </div>
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After I got most of the fairings off, I searched for a manual to help debug what may be preventing it from starting.<span style="-webkit-composition-fill-color: rgba(175, 192, 227, 0.230469); -webkit-composition-frame-color: rgba(77, 128, 180, 0.230469); -webkit-tap-highlight-color: rgba(26, 26, 26, 0.292969);"> I found a manual from this <a href="http://zx6r.com/service-manuals/46343-service-manual-zx600r-c-series.html" target="_blank">forum</a> for a 1998 Kawasaki Ninja. I also found one on the </span><span style="-webkit-composition-fill-color: rgba(175, 192, 227, 0.230469); -webkit-composition-frame-color: rgba(77, 128, 180, 0.230469); -webkit-tap-highlight-color: rgba(26, 26, 26, 0.292969);"><span style="-webkit-composition-fill-color: rgba(175, 192, 227, 0.230469); -webkit-composition-frame-color: rgba(77, 128, 180, 0.230469); -webkit-tap-highlight-color: rgba(26, 26, 26, 0.292969);"><a href="http://kawasaki.com/kawasakinew/accessories2/PCCatItems.aspx?intCatalogID=1&intCatalogType=4&ProductTypeID=14&ModelMarketingID=166&ModelYear=1989&ModelCode=ZX600C2" target="_blank">Kawasaki</a> </span>site that was closer to a 1989 Ninja make. I ended up using this <a href="https://dl.dropboxusercontent.com/u/58105293/ZX600RC1.pdf" target="_blank">manual</a>.</span><br />
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When I took this picture, I was trying to capture what I thought it's future would be like. Engine-less, and on its way to an electric paradise. But... I guess now that it's running, it's going to keep its guts.<br />
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The previous owner said he had replaced the battery a year ago. It didn't make the bike run, so it was left in a garage for a year. Dgonz and I checked the battery voltage and found it at 6.63V. For a 12V motorcycle battery, 6.63V is pretty much dead.<br />
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(Before Dgonz showed up and convinced me to test the engine, I was ready to take it all apart and convert it to electric) Thanks Dgonz!!! <br />
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So we tried one of the many Smart Dane batteries lying around MITERS. Since the removed fairings had all the electrical indicators, I plugged the tachometer set in to get feedback. And there were lights! It seemed like all the electrical systems worked: the neutral indicator, oil indicator, blinkers (relays were clicking fast without the resistance of the light, and horn were all working. <br />
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We then tested the starter motor to see if the engine would even turn. And the battery kind of fizzled...<br />
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The starter motor sounded like it was turning very slightly, then drawing more than 30A and blowing the Dane battery (Dane actually designed these batteries when he worked for A123). Because Dane's batteries are smart, they would cut out and read 0.0V afterwards. Dgonz "woke them up" by connecting them to a 13.3V power supply.<br />
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These are casualties of our efforts... <br />
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I left my laptop on the hood of a car to have the manual handy while we debugged. I didn't even notice when that car started to back up and drive away! Thankfully they noticed before going to far. </div>
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After reaching a dead end on the electric start, Dash (a friend of Mars who works on mopeds), Dgonz, Thomas, and Mars helped me push start it. This entailed two people running behind, while the rider shifted to first, quickly pulled in the clutch, and twisted the throttle.<br />
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When we first tried to push start it, the engine purred like it was almost ready to start. This ruled out the possibility that the engine couldn't turn which was a relief. Maybe there's too much oxide built up on the pistons which prevented the starter motor from turning the engine and drawing infinite current. </div>
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We tried a couple more times with longer stretches to push. The engine purred louder as we kept pushing, but it never took off. Dash pointed out, "An engine needs three things, Compression, Spark, and Fuel." So, I checked the spark plugs to see if the looked happy.<br />
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The spark plugs were easily accessible by moving the gas tank over a bit. They were pretty deep inside the engine. While I was trying to figure out the bolt size, I dropped a socket in the spark plug hole. I went socket fishing with a magnet on a stick. For future reference, the wrench size was 19mm.<br />
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The <a href="http://d136nqpz68vrmx.cloudfront.net/digital_assets/How-to-Read-a-Spark-Plug.gif" target="_blank">spark plugs</a> looked in pretty decent condition. To test whether or not the engine had spark, we pulled out a spark plug and grounded it. Then tried push starting it again with a third person running along checking the plug for a blue spark.<br />
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Since the plug wasn't <strike>plugging</strike> threaded into the engine, we could smell gas fairly strongly. That indicated that the engine was getting plenty of fuel. After this test, we concluded that the engine was getting all three necessary ingredients. Then Mars suggested we hook a battery up, because some bikes require a battery to run. In effect, the battery acts as a wire or capacitor just completing a circuit.<br />
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So we strapped a "stupid" battery (one that won't safely cut out like Dane's batteries) to the gas tank with some electrical tap and gave it another try.<br />
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So... Yeah... It runs :) Now what am I going to do!?!? Rev it up and ride around the block (with a helmet of course).<br />
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The previous owner of the bike dropped it off at MITERS around 9:45AM, and I had it running before sundown. That's enough fun for one Sunday.<br />
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It joins the other bikes parked outside MITERS. </div>
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It seems I have a similar problem Charles has. Except that I didn't put in nearly the same amount of time and effort to get it running. I wonder what the previous owner did to deem this bike junkyard worthy? </div>
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Well... the next thing to do is read up on the manual, and figure out how to get the electric starter working so I don't have to push start it every time. </div>
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Jaguar Kristellerhttp://www.blogger.com/profile/08428337775851273522noreply@blogger.com1tag:blogger.com,1999:blog-2823741957408378785.post-80553098637986268842013-07-14T00:44:00.001-04:002013-07-14T00:45:22.834-04:00MIT Museum: Electric Orbit Wheel Demonstrations<div class="separator" style="clear: both; text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0cvVJkjr19ABCglyUovq7LPl-mmiF01FdMTIyfgA4sayFVTtezug5kMq2COtzGCzKDEHlnK0WfuJT3xZJlXV4AMMS5nsxFRqZN_3Lrfu40YhUD-xlt3FmBCs0Dj41u-XhiSYVZYrv7nE/s1600/MITMuseum_041713_101.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="426" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0cvVJkjr19ABCglyUovq7LPl-mmiF01FdMTIyfgA4sayFVTtezug5kMq2COtzGCzKDEHlnK0WfuJT3xZJlXV4AMMS5nsxFRqZN_3Lrfu40YhUD-xlt3FmBCs0Dj41u-XhiSYVZYrv7nE/s640/MITMuseum_041713_101.jpg" width="640" /></a></div>
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After seeing the <a href="http://kriste11er.blogspot.com/p/completed_21.html#electric_orbit_wheel" target="_blank">Electric Orbit Wheels</a> at Tech Fair 2013, the Director of Education and Public Programs at the MIT Museum, Brindha Muniappan, invited me to the Play Day at the MIT Museum on April 17th to do a demonstration. I didn't hesitate to accept. Since then, I've been demonstrating the orbit wheels and the most recent <a href="http://kriste11er.blogspot.com/2013/05/glowboard-welded-steel-mini-skateboard.html" target="_blank">GlowBoard</a> every other weekend at the museum. It reminds me of the <a href="http://www.kriste11er.com/kriste11er/2011/community_service/community_service.htm" target="_blank">good old FIRST days</a> when my team, 3705 Porhtal, would take our robot around to various schools around the state of Alaska and teach robotics. </div>
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<br />Jaguar Kristellerhttp://www.blogger.com/profile/08428337775851273522noreply@blogger.com0tag:blogger.com,1999:blog-2823741957408378785.post-54604717229078707012013-06-20T11:50:00.000-04:002013-07-05T14:15:35.318-04:00Earth in the Foreground: How I Managed a Research Trip to Alaska<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
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<tr><td class="tr-caption" style="font-size: 13px;">Flying into a Beautiful, Sunny, Hot Fairbanks</td></tr>
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This project requires a good introduction of Ed Moriarty. I first met Ed at a summer camp at the University of Alaska Fairbanks (UAF). At ASRA (Alaska Summer Research Academy), Ed was everywhere. He would stop by every module checking in on whatever cool things we were up to. He was also very involved in and taught the Underwater ROV and Extreme Photography Modules for a few years. Ed has done a bunch of cool things in Alaska to spread awareness and get kids excited/inspired about science and technology. </div>
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Recently, we were talking about ASRA, and he had mentioned that he's been dreaming about getting a 24 hour time-lapse video of the sun above the Arctic Circle in Alaska for quite a long time. So, I looked into it, received a grant from the MIT's CAMIT Arts Grants, and started building a device to take a moving time lapse. A couple weeks passed, and I hopped on a plane to Fairbanks, 181 miles below Finger Mountain and our decided video location. Not only is Fairbanks a good location for setting up equipment, but it's also the location of my family's house. Here's the story of my adventures researching back home.</div>
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I don't normally take pictures outside an airplane window. However, Ed told me to take pictures... "Take LOTS of pictures." So why not...</div>
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Waking up after a 2 hour nap, 10 hours of flying and 43 hours of sleepless exhaustion (prior to the nap), I looked out my window and saw this...</div>
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Somewhere down near Mt. Saint Elias around Southeast Alaska.<br />
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<tr><td class="tr-caption" style="font-size: 13px;">Merging Glaciers! Whoah!</td></tr>
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<tr><td class="tr-caption" style="font-size: 13px;">The Alcan Highway</td></tr>
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My Dad's driving a new truck up this road from Portland.<br />
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I could just barely make out a faint orange glow through the smoke.<br />
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<a href="http://1.bp.blogspot.com/-apeGumARiCA/UcMV2SwlFbI/AAAAAAAABcg/mmazOqztAz4/s1600/2013-06-19+16.04.44.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-apeGumARiCA/UcMV2SwlFbI/AAAAAAAABcg/mmazOqztAz4/s640/2013-06-19+16.04.44.jpg" width="640" /></a></div>
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I wonder if there will be a faint smoke smell in Fairbanks...<br />
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<tr><td><a href="http://2.bp.blogspot.com/-3kWOtTEglwQ/UcMV3mjLmYI/AAAAAAAABco/O9QG969nFq4/s1600/2013-06-19+16.24.44.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="478" src="http://2.bp.blogspot.com/-3kWOtTEglwQ/UcMV3mjLmYI/AAAAAAAABco/O9QG969nFq4/s640/2013-06-19+16.24.44.jpg" width="640" /></a></td></tr>
<tr><td class="tr-caption" style="font-size: 13px;">Tananana River</td></tr>
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Funny thing about the name of the Tanana River (and essentially any other river in Alaska ending with "na"): The Native Alaskan equivalent to "river" is "na"; therefore "the Tanana" is really the "Tana River"... not the Tana River River. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwRlQ620l16Ri0N124WfOkdOSqkprpu2RqLWZctCM3wOcZRqgs2V1dA8pGndzqiawWWGrEoen2kKiVwoW29KebLjcDE2behSVMbD-23KQkRHF7gKxAAs36k6-o3nmn1hQFPM27sw_DY68/s1600/2013-06-19+15.36.42.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwRlQ620l16Ri0N124WfOkdOSqkprpu2RqLWZctCM3wOcZRqgs2V1dA8pGndzqiawWWGrEoen2kKiVwoW29KebLjcDE2behSVMbD-23KQkRHF7gKxAAs36k6-o3nmn1hQFPM27sw_DY68/s640/2013-06-19+15.36.42.jpg" width="640" /></a></div>
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Fort Wainright</div>
And... basically all of Fairbanks.<br />
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<a href="http://2.bp.blogspot.com/-eHpGIh-RSjY/UcL1OiPSkfI/AAAAAAAABZI/juRxGpJsHTk/s1600/2013-06-19+15.38.20.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://2.bp.blogspot.com/-eHpGIh-RSjY/UcL1OiPSkfI/AAAAAAAABZI/juRxGpJsHTk/s640/2013-06-19+15.38.20.jpg" width="640" /></a></div>
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Chena Hot Springs road. </div>
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<tr><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOyeYgehBwkE4ajH_AG27hSOqfqkCxBNWUURd34BCskYXsin2Ulsr4wGgmBrUPl7ZeUv9tLclwdopIz9_Wtlg98QUJblcG8oIPXtOsEc6uroxs2JTV3i9LIIHUHtke8vbmCN9owJqSXjg/s1600/2013-06-19+15.39.02.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgOyeYgehBwkE4ajH_AG27hSOqfqkCxBNWUURd34BCskYXsin2Ulsr4wGgmBrUPl7ZeUv9tLclwdopIz9_Wtlg98QUJblcG8oIPXtOsEc6uroxs2JTV3i9LIIHUHtke8vbmCN9owJqSXjg/s640/2013-06-19+15.39.02.jpg" width="640" /></a></td></tr>
<tr><td class="tr-caption" style="font-size: 13px;">My Neighborhood</td></tr>
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McGrath (and potentially my old childhood home on Frog Pond Circle) with Fairbanks in the upper distance and the airstrip on the upper right. </div>
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<tr><td><a href="http://2.bp.blogspot.com/-pSlvrrrcppo/UcL1Sqzx2qI/AAAAAAAABZY/Wptu9MRhzvw/s1600/2013-06-19+15.39.12.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="478" src="http://2.bp.blogspot.com/-pSlvrrrcppo/UcL1Sqzx2qI/AAAAAAAABZY/Wptu9MRhzvw/s640/2013-06-19+15.39.12.jpg" width="640" /></a></td></tr>
<tr><td class="tr-caption" style="font-size: 13px;">MY HOUSE!!! :D</td></tr>
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I was so excited to see my house! I always wondered whether I would get to fly over Fairbanks and see it. So awesome :) great way to start the trip. </div>
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<tr><td><a href="http://4.bp.blogspot.com/-XtIHLBYzmP4/UcL1WrnWypI/AAAAAAAABZs/ApO32CCrqaY/s1600/2013-06-19+15.40.18.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="478" src="http://4.bp.blogspot.com/-XtIHLBYzmP4/UcL1WrnWypI/AAAAAAAABZs/ApO32CCrqaY/s640/2013-06-19+15.40.18.jpg" width="640" /></a></td></tr>
<tr><td class="tr-caption" style="font-size: 13px;">Fairbankorage or Anchorbanks</td></tr>
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The developed part in the center of the photograph used to look like the bottom of the photograph until a few years ago. They call it Fairbankorage or Anchorbanks, because, like a tumor of populated Anchorage, it's growing in the heart of the Golden Valley. </div>
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<a href="http://2.bp.blogspot.com/-m6i8TJhAnKI/UcL1V25STUI/AAAAAAAABZg/IPMtmKCMYbw/s1600/2013-06-19+15.40.53.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://2.bp.blogspot.com/-m6i8TJhAnKI/UcL1V25STUI/AAAAAAAABZg/IPMtmKCMYbw/s640/2013-06-19+15.40.53.jpg" width="640" /></a></div>
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<tr><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXxKCP8WP4KbwDVr9DvoDQP7h_-4tP8G7_Vp7FEb6Vrbyq7TU2jNL8ZtI3EOzInCdsXHVLVB4RHz2pPfmHYv2LBOUdWsBX7afppptIrAk2DHLa4cEeqWevtJklEvUze2Dy4P3y8V8NMgI/s1600/2013-06-19+15.41.06.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjXxKCP8WP4KbwDVr9DvoDQP7h_-4tP8G7_Vp7FEb6Vrbyq7TU2jNL8ZtI3EOzInCdsXHVLVB4RHz2pPfmHYv2LBOUdWsBX7afppptIrAk2DHLa4cEeqWevtJklEvUze2Dy4P3y8V8NMgI/s640/2013-06-19+15.41.06.jpg" width="640" /></a></td></tr>
<tr><td class="tr-caption" style="font-size: 13px;">Che River River</td></tr>
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I might get to go kayaking on the Chena with my Mom. </div>
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<a href="http://1.bp.blogspot.com/-hTtsShS9y_o/UcL1bPMXJZI/AAAAAAAABaE/ArQvakeVSZ8/s1600/2013-06-19+15.44.51.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-hTtsShS9y_o/UcL1bPMXJZI/AAAAAAAABaE/ArQvakeVSZ8/s640/2013-06-19+15.44.51.jpg" width="640" /></a></div>
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Touchdown... I knew that the Fairbanks International Airport was small... but now that I think about it, it's tiny! Maybe I've just acclimated to Boston's huge population. </div>
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90 degrees outside! Glad to be home :)...<br />
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Jaguar Kristellerhttp://www.blogger.com/profile/08428337775851273522noreply@blogger.com0tag:blogger.com,1999:blog-2823741957408378785.post-48041056939714204592013-05-31T03:40:00.001-04:002013-06-01T18:43:45.945-04:00Servo Actuated Gauge: Part 2<div class="separator" style="clear: both; text-align: left;">
I finished up the wireless servo actuated air pressure gauge. The last things remaining were to finish the transmitter, and make a small transmitter box to house the transmitter PCB with a dial and markings corresponding to the servo actuated gauge. </div>
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<iframe allowfullscreen="" frameborder="0" height="360" src="http://www.youtube.com/embed/f8_oos8ARPY?rel=0" width="640"><br />
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To summarize Part 1 of the servo actuated gauge project: </div>
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I fixed up a mini servo and installed it in the gauge with a four-bar-linkage. I also ordered a Hobby King GT-2 2.4Ghz 2Ch Tx & Rx (the same one I used for the Electric Orbit Wheels) to control the servo from a distance. After it came in, I could start working with the transmitter end.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8nGsac0E39OBybGx6VcPZxBkNaVC-Fag_FZ8Yer44zKcGJuw006w9MUHnpAT0NHDqM8eTMh6tma13jl4kA48Qf6I0aDbH6CWmEfaNph3sqz0PbDvx8i7EMHLJ4WCf86Uu5IX0oGPd1JM/s1600/2013-05-29+00.54.33.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8nGsac0E39OBybGx6VcPZxBkNaVC-Fag_FZ8Yer44zKcGJuw006w9MUHnpAT0NHDqM8eTMh6tma13jl4kA48Qf6I0aDbH6CWmEfaNph3sqz0PbDvx8i7EMHLJ4WCf86Uu5IX0oGPd1JM/s640/2013-05-29+00.54.33.jpg" width="640" /></a></div>
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The Hobby King controller comes with a handy little binding device to connect the servo and ground on channel three of the receiver. I moved one of the leads to the center to make a battery plug. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqWGu9B07j1X4evX1V8pbhCDlgH2921u7Q1UgS94ni9DSmWp6uJqJuZEGLQEwOKew9bv-s1E3H-lxB9KKn_Ufh3pFyLP8XA1iDalVeC6qmIj0Xm1A3E2X98G0Q8H-trK2AYZPAmvZlt7o/s1600/2013-05-31+03.15.21.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjqWGu9B07j1X4evX1V8pbhCDlgH2921u7Q1UgS94ni9DSmWp6uJqJuZEGLQEwOKew9bv-s1E3H-lxB9KKn_Ufh3pFyLP8XA1iDalVeC6qmIj0Xm1A3E2X98G0Q8H-trK2AYZPAmvZlt7o/s640/2013-05-31+03.15.21.jpg" width="478" /></a></div>
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The receiver calls for between 5V and 6V. So I quickly made a voltage divider with a 24 kΩ and a 15 kΩ resistor to get an output voltage of 5.5V (I got the resistors from the Edgerton Center Rm. 4-409). </div>
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<a href="http://4.bp.blogspot.com/-RBOlxad4L48/UahCw2sipjI/AAAAAAAABTA/OseVmjSsvt4/s1600/2013-05-29+00.58.44.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://4.bp.blogspot.com/-RBOlxad4L48/UahCw2sipjI/AAAAAAAABTA/OseVmjSsvt4/s640/2013-05-29+00.58.44.jpg" width="640" /></a></div>
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<a href="http://3.bp.blogspot.com/-IJMkBKMRJDo/UahCxGYWMAI/AAAAAAAABTE/AKScDufaM9k/s1600/2013-05-29+01.04.21.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://3.bp.blogspot.com/-IJMkBKMRJDo/UahCxGYWMAI/AAAAAAAABTE/AKScDufaM9k/s640/2013-05-29+01.04.21.jpg" width="640" /></a></div>
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Testing the voltage divider.</div>
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I think the 5.5V voltage divider interferes with the transmitter and receiver binding. Because I don't get the same ghost issues when I use 6V from the 12V pack. I ended up scrapping the voltage divider and using the full 9V. It seemed to handle it fine. </div>
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<a href="http://2.bp.blogspot.com/-9-S30IZtWZM/UahDPq-klzI/AAAAAAAABU0/23Ho-az66x0/s1600/2013-05-30+02.47.30.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://2.bp.blogspot.com/-9-S30IZtWZM/UahDPq-klzI/AAAAAAAABU0/23Ho-az66x0/s640/2013-05-30+02.47.30.jpg" width="640" /></a></div>
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I didn't want to use the Hobby King controller for the final controller, so I used an old plastic soap container. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvek6tM-l9YtRELJMcS-AoCp6P9iIMbZRJ4_2FF9YovpjTtL3yD-jJOxCHovZtKIstoANKeSv47r5ek1WxFVc4wTAy2PUxaymQJ2qQAklNwJ5N_BcDYb8R3NLk5B2DTxxyiOBbpJsaNXk/s1600/2013-05-30+02.47.22.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgvek6tM-l9YtRELJMcS-AoCp6P9iIMbZRJ4_2FF9YovpjTtL3yD-jJOxCHovZtKIstoANKeSv47r5ek1WxFVc4wTAy2PUxaymQJ2qQAklNwJ5N_BcDYb8R3NLk5B2DTxxyiOBbpJsaNXk/s640/2013-05-30+02.47.22.jpg" width="640" /></a></div>
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The transmitter PCB and batteries barely fit. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXppCp7t9PI0QY0niSDSjfgEnK885_wQiFtbUjMXJYIusIT-Fk5c2usWerEyWGl8zX0BLms6scnd3UhCzREad8mj1D01kA0puY644-7IDS9w19VN5IbLjse0xC1TY5zR_wTDi06ZpklLw/s1600/2013-05-30+14.01.53.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgXppCp7t9PI0QY0niSDSjfgEnK885_wQiFtbUjMXJYIusIT-Fk5c2usWerEyWGl8zX0BLms6scnd3UhCzREad8mj1D01kA0puY644-7IDS9w19VN5IbLjse0xC1TY5zR_wTDi06ZpklLw/s640/2013-05-30+14.01.53.jpg" width="640" /></a></div>
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I changed my mind about the soap container. It looks a little to sketchy and I wanted to hide all the electronics. Rather than having the transparent plastic, I took apart a former transformer's metal housing. This will also allow me to use the 12V AA battery pack which might help with some of the ghost binding problems. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEheUuejUtdOw4mLBEOcx-fHHwMRp6-7zylMpYxjCE4HOmPYl9yRqsjcmW0PkuSdS4qTXrwxuLjmQXc54_8H6QNqe_v4anEYS2AWrtyAk_kTDVxDKDjbCmT1hF_EihPZ0-bzRLYrCVBoie8/s1600/2013-05-30+14.02.02.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEheUuejUtdOw4mLBEOcx-fHHwMRp6-7zylMpYxjCE4HOmPYl9yRqsjcmW0PkuSdS4qTXrwxuLjmQXc54_8H6QNqe_v4anEYS2AWrtyAk_kTDVxDKDjbCmT1hF_EihPZ0-bzRLYrCVBoie8/s640/2013-05-30+14.02.02.jpg" width="640" /></a></div>
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I crufted a bunch of power supplies seeking for 250wv 330uF capacitors for a broken 42" LG TV. So I cut up some of their covers to make sides for the transformer box.</div>
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<a href="http://1.bp.blogspot.com/-K3BhLzx4Ba4/UahCylB3V8I/AAAAAAAABTk/mEnUGBnSCiw/s1600/2013-05-30+16.02.34.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-K3BhLzx4Ba4/UahCylB3V8I/AAAAAAAABTk/mEnUGBnSCiw/s640/2013-05-30+16.02.34.jpg" width="640" /></a></div>
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My Dad always used to say, "Keep your work space clean". Hmmm...</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgD6FB6wzPvZIRto0_m0HEay7glL3ldS8MchiMxaFN41-7CKTdWzxgBwatHlOJwVDBVWfqcx7rCRZRYXJ4yUGfDIACl_o201rVkepnDRdV7g48jFYNFddN-nYhk129BYv8zhfy3Alb1UHg/s1600/2013-05-30+18.06.25.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgD6FB6wzPvZIRto0_m0HEay7glL3ldS8MchiMxaFN41-7CKTdWzxgBwatHlOJwVDBVWfqcx7rCRZRYXJ4yUGfDIACl_o201rVkepnDRdV7g48jFYNFddN-nYhk129BYv8zhfy3Alb1UHg/s640/2013-05-30+18.06.25.jpg" width="640" /></a></div>
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One problem with having a metal container rather than a plastic container... things short! I taped up parts that might come in contact with the metal box. </div>
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<a href="http://1.bp.blogspot.com/-2ggi95l4EH4/UahCzeuYgWI/AAAAAAAABTw/_Ok_o5YZUas/s1600/2013-05-30+18.06.38.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-2ggi95l4EH4/UahCzeuYgWI/AAAAAAAABTw/_Ok_o5YZUas/s640/2013-05-30+18.06.38.jpg" width="640" /></a></div>
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I hot glued a piece of acrylic I had lying around to the bottom of the transmitter PCB. Funny thing about hot gluing acrylic, it warps and bends from the heat. </div>
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I then glued all the transmitter components inside the metal transformer box. </div>
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Here's a picture of the transmitter box and receiver. I figured out some of the binding issues with the receiver and transmitter. I had previously thought that switching between the same potentiometers from identical <a href="http://www.hobbyking.com/hobbyking/store/uh_viewitem.asp?idproduct=15141">remote controllers</a> wouldn't change anything. However, it was interfering with the binding between transmitter and receiver. It turned out that the potentiometer had to be centered because on the remote controller there were springs that would ensure the potentiometers ended up with the center specific resistance. The same thing would happen if you were to pull the trigger and try to bind the transmitter and receiver (which seems very odd to do with the device when its all professionally packaged up, but easy to go unnoticed when hacked). </div>
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I stuffed the RC receiver in the hacked air pressure gauge and cut out a space in the cover for the servo. Rather than adding a switch, I just glued the 9V on the outside so the clip can be easily removed.<br />
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Control box with knob and corresponding needle values labeled. </div>
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Because the gauge used to be an air pressure gauge, it was geared for torque inside. This allowed for the small flex in metal tubing (when air pressure was applied) to have a greater affect on the needle. However, in this case it makes the system very sensitive. I can turn the needle 300 degrees with only turning the control potentiometer 20 degrees.</div>
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It works. Though, I may change the sensitivity later on. </div>
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Jaguar Kristellerhttp://www.blogger.com/profile/08428337775851273522noreply@blogger.com0tag:blogger.com,1999:blog-2823741957408378785.post-32752143336559468032013-05-27T03:03:00.002-04:002013-05-31T03:54:20.936-04:00RC Servo Actuated Air Pressure Gauge<div class="separator" style="clear: both; text-align: center;"></div>As part of my Undergraduate Research Opportunity (UROP) at the Computer Science and Artificial Intelligence Laboratory at MIT, I took apart an air pressure gauge and added a servo to remotely move the needle. I hacked the parts used in the air pressure gauge to make a four-bar-linkage with a servo I crufted from the remains of Charles' <a href="http://www.etotheipiplusone.net/?p=2730">2.00GoKart</a> class. I'm not sure if I can reveal the intentions of doing this for secrecy of the CSAIL project, so I better be safe and not mention it.<br />
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<div>I was tempted to make this a full out Arduino project with pulse width modulation and all. However, I decided it would be quicker and more worth my time to use the RC radio receiver/transmitter system. The Hobby King <a href="http://www.hobbyking.com/hobbyking/store/__10608__Hobby_King_GT_2_2_4Ghz_2Ch_Tx_Rx.html">RC system</a> I used for my electric orbit wheels is basically a micro-controller built to do just this (servo controlled by potentiometer throttle at a distance).<br />
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<div style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvU1tM3ubNUcLjbIME88EuRl4UqPN0vAmdrydFP5fhMbOqszVy91aDq7UXLBYLBaiMQIPol2SClyRa1B_yedPqQHMV-asmt2EwNX5WUBYkD6Q7UiO0OBv_z7C5w0t20R-cmsZtRTZ_skU/s1600/2013-05-26+14.39.29.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjvU1tM3ubNUcLjbIME88EuRl4UqPN0vAmdrydFP5fhMbOqszVy91aDq7UXLBYLBaiMQIPol2SClyRa1B_yedPqQHMV-asmt2EwNX5WUBYkD6Q7UiO0OBv_z7C5w0t20R-cmsZtRTZ_skU/s640/2013-05-26+14.39.29.jpg" width="640" /></a></div><div style="text-align: left;"><br />
</div><div style="text-align: left;">Before committing to installing the servo in the gauge, I tested whether or not it actually worked. I used this handy little servo tester I found on the Stata loading dock. However, the tester didn't work (probably why it was left on the Stata loading dock). </div><div style="text-align: left;"><br />
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</div><div style="text-align: left;">Instead, I used my <a href="http://kriste11er.blogspot.com/p/completed_21.html#electric_orbit_wheel">Electric Orbit Wheel</a> radio receiver/transmitter system. </div><div style="text-align: center;"><br />
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<div style="text-align: left;">Now that I know it works, time to install it. </div></div></div><div style="text-align: center;"><br />
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<tr><td style="text-align: center;"><a href="http://1.bp.blogspot.com/-2gti9GGostA/UaL6SNlg6bI/AAAAAAAABSs/YcQ0xZ3k9n0/s1600/2013-05-26+14.55.57.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="478" src="http://1.bp.blogspot.com/-2gti9GGostA/UaL6SNlg6bI/AAAAAAAABSs/YcQ0xZ3k9n0/s640/2013-05-26+14.55.57.jpg" width="640" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Either that's a huge thumb, or a tiny servo. </td></tr>
</tbody></table><div style="text-align: left;">Unfortunately, while in the process of taking the servo off the mechanism it was attached to, I broke the top gear. Without the top gear connection, the servo can not turn the servo horn (basically rendering the servo "kaput"). So I turned a small piece of nylon on the lathe to fix it up. </div><div style="text-align: left;"><br />
</div><div style="text-align: left;">Here's the plan. </div><div style="text-align: left;"><br />
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</div><div class="separator" style="clear: both;">Because I miss the good old days in FIRST, I wrote a little engineering notebook style note to document my method for fixing the servo.</div><div class="separator" style="clear: both; text-align: center;"><br />
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</div><div class="separator" style="clear: both; text-align: left;">Removed the cover, press fit the nylon coupling onto the broken gear, drilled a bigger hole in the cover, used super glue to secure the servo horn (while still preserving the servo horn's changeable angle), and attached it to the remaining air pressure gauge parts to make a four-bar-linkage. </div><br />
<div style="text-align: center;"><a href="http://kriste11er.blogspot.com/2013/05/servo-actuated-gauge-part-2.html">Link to Part 2</a></div><div class="separator" style="clear: both; text-align: center;"><br />
</div> A fairly quick and easy build finished. QEDJaguar Kristellerhttp://www.blogger.com/profile/08428337775851273522noreply@blogger.com1tag:blogger.com,1999:blog-2823741957408378785.post-21202271436539849712013-05-06T01:07:00.002-04:002013-05-10T00:18:21.767-04:00GlowBoard: A Welded Steel Mini-Skateboard<div class="separator" style="clear: both; text-align: center;">
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibHll-80xd9A_8XYJkiCU2CNJL-nj0naKaz_jyQKETtSbNgfHhKCn3wLviPo0vUuEQSb3fI_ALI_BYombpEt1MZvCa4lyBLDsjP8xMbGS72PJk5VjiRyDQ1huoZpyvT4UUgFZe3MxQE04/s1600/8721582833_1400bc875b_o.jpg" imageanchor="1"><img border="0" height="422" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEibHll-80xd9A_8XYJkiCU2CNJL-nj0naKaz_jyQKETtSbNgfHhKCn3wLviPo0vUuEQSb3fI_ALI_BYombpEt1MZvCa4lyBLDsjP8xMbGS72PJk5VjiRyDQ1huoZpyvT4UUgFZe3MxQE04/s640/8721582833_1400bc875b_o.jpg" width="640" /></a></div>
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Inspired by Ben's <a href="http://build-its-inprogress.blogspot.com/search/label/PocketBoard">PocketBoard</a>, I decided to make a small skateboard in order to scavenge free food faster. It all started when my roommate crufted an old skateboard from his fraternity. I went on Ebay and found some awesome glow-in-the-dark 70x51 mm <a href="http://www.ebay.com/itm/130789389720?ssPageName=STRK:MEWNX:IT&_trksid=p3984.m1439.l2648">skateboard wheels</a>. I wanted to make the deck such that I could maximize the visibility of the wheels. I recently learned how to MIG and TIG weld (thanks to Mars) and after finding some steel rings in MITERS' scrap metal I decided to practice my welding technique (before welding together my future electric motorcycle). I made a wire-frame deck with supporting steel rods underneath and the negative piece of a water jetted steel wrench for the truck plates. </div>
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<a href="http://1.bp.blogspot.com/-m4EBvcP_RrE/UYxzRIp9oLI/AAAAAAAABO8/SieJSXhSSIs/s1600/8722704452_11dc788306_o.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="422" src="http://1.bp.blogspot.com/-m4EBvcP_RrE/UYxzRIp9oLI/AAAAAAAABO8/SieJSXhSSIs/s640/8722704452_11dc788306_o.jpg" width="640" /></a></div>
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For more on the build process...</div>
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Here's the board my roommate crufted.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0Xx3u9syV_dcSTo9Ia1Tfb6OdhckFLF-modEcjDANxo4ICh-P3ig2Ea26iOBT87oDKvzTjbuZUkT5Mc1WbV-jz6tCStPM6qdIwqCiFhwyatgulQqyC6RXTS95mXq4EmsDp37dOpOAfX8/s1600/2013-04-21+01.40.05.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0Xx3u9syV_dcSTo9Ia1Tfb6OdhckFLF-modEcjDANxo4ICh-P3ig2Ea26iOBT87oDKvzTjbuZUkT5Mc1WbV-jz6tCStPM6qdIwqCiFhwyatgulQqyC6RXTS95mXq4EmsDp37dOpOAfX8/s640/2013-04-21+01.40.05.jpg" width="640" /></a></div>
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The trucks are in good shape and are not very stiff, which improves the board's turning radius. I robbed the skateboard of it's trucks, reducing it's identity down to a swing seat on floor <a href="http://web.mit.edu/5west/www/">QED or w5</a>. </div>
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The glow-in-the-dark wheels are really cool looking... in the dark.<br />
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<a href="http://1.bp.blogspot.com/-Dq1yApzoflw/UYcjGIYaJUI/AAAAAAAABCQ/CL4sGiseBk8/s1600/2013-04-27+20.10.39+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-Dq1yApzoflw/UYcjGIYaJUI/AAAAAAAABCQ/CL4sGiseBk8/s640/2013-04-27+20.10.39+-+Copy.jpg" width="640" /></a></div>
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The rings are about 7.5 inches in diameter. </div>
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<a href="http://3.bp.blogspot.com/-kH7pbf6N_PQ/UYcjG6ezhQI/AAAAAAAABCY/jm402aCHe0E/s1600/2013-04-27+21.23.03+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://3.bp.blogspot.com/-kH7pbf6N_PQ/UYcjG6ezhQI/AAAAAAAABCY/jm402aCHe0E/s640/2013-04-27+21.23.03+-+Copy.jpg" width="640" /></a></div>
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I cut a ring in half and hammered the two halves to bigger diameters. I clamped a ridiculous steel steering wheel-like thing to the vice to use as an anvil.<br />
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<a href="http://1.bp.blogspot.com/-4HZ_GZ9NvIw/UYcjf4PbPLI/AAAAAAAABDA/rHK6fT9JfiI/s1600/2013-04-27+22.01.19+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-4HZ_GZ9NvIw/UYcjf4PbPLI/AAAAAAAABDA/rHK6fT9JfiI/s640/2013-04-27+22.01.19+-+Copy.jpg" width="640" /></a></div>
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<a href="http://3.bp.blogspot.com/-1qv0KLnEJGM/UYcjQr40qII/AAAAAAAABCo/MzwzwzTNaY8/s1600/2013-04-27+21.29.50+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://3.bp.blogspot.com/-1qv0KLnEJGM/UYcjQr40qII/AAAAAAAABCo/MzwzwzTNaY8/s640/2013-04-27+21.29.50+-+Copy.jpg" width="640" /></a></div>
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I messed around with different orientations of the steel rings. This is what it will generally look like when it's finished. Time to weld! :)</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5SybsPgCYYoCsta3x-7xIGxlB-nc9g5J4St_sxuQdlnal3jyIyumxZESkwRS_viqrkkEmrcdHD8ZCZ7DI_PK0O8cnknG5EgPFZrAidR7RIW5WfYSwKVYmH2HcOEU9umRPerz2BdGuAqs/s1600/2013-04-27+22.00.49+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi5SybsPgCYYoCsta3x-7xIGxlB-nc9g5J4St_sxuQdlnal3jyIyumxZESkwRS_viqrkkEmrcdHD8ZCZ7DI_PK0O8cnknG5EgPFZrAidR7RIW5WfYSwKVYmH2HcOEU9umRPerz2BdGuAqs/s640/2013-04-27+22.00.49+-+Copy.jpg" width="640" /></a></div>
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My MIG welds aren't the best, but they will do. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhq9W66IJZxZ7UcfxsQqwFPmOXyfEMu5GtDc3ka3swFARrbsskO-IbsCc91Zejto3NxCPcSR_w-EMdgtOPsFw6PmjSMkwO307S54Lae7rUO2cOD_W4f8DTOsO6mq6F2DQY_rNn174m1mIo/s1600/2013-04-27+22.17.02+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhq9W66IJZxZ7UcfxsQqwFPmOXyfEMu5GtDc3ka3swFARrbsskO-IbsCc91Zejto3NxCPcSR_w-EMdgtOPsFw6PmjSMkwO307S54Lae7rUO2cOD_W4f8DTOsO6mq6F2DQY_rNn174m1mIo/s640/2013-04-27+22.17.02+-+Copy.jpg" width="640" /></a></div>
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I found a long steel 3" wide 0.1" thick (which happens to have a wrench cut out of it) that fits between the welded rings. I want to make it out of one piece, so I can use the mill to ensure the truck holes are lined up (minimize drifting to one side or the other). After I weld the steel plate in place, I will cut out the wrench part to minimize the weight.</div>
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<a href="http://1.bp.blogspot.com/-rDwE_SMI2X4/UYcjq5b7jdI/AAAAAAAABDQ/dyTcbYqlhK8/s1600/2013-04-27+22.18.38+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-rDwE_SMI2X4/UYcjq5b7jdI/AAAAAAAABDQ/dyTcbYqlhK8/s640/2013-04-27+22.18.38+-+Copy.jpg" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIwMtHZPphNe3MxuRd0CuNdSm7zRGDEJG-Fw3w0Ca_7KuIx19xekO8Gr-Yjc7SNPEIPQe4ySj6PJkg5aLWyO10PXAZNLPdPSpXExV4JtoDOSyzHTP2ovi3QYY6jEitRoYNaQ1Fac7xuC8/s1600/2013-04-27+22.24.58+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIwMtHZPphNe3MxuRd0CuNdSm7zRGDEJG-Fw3w0Ca_7KuIx19xekO8Gr-Yjc7SNPEIPQe4ySj6PJkg5aLWyO10PXAZNLPdPSpXExV4JtoDOSyzHTP2ovi3QYY6jEitRoYNaQ1Fac7xuC8/s640/2013-04-27+22.24.58+-+Copy.jpg" width="478" /></a></div>
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Measure a lot, or figure out a way to deal with the consequences... In order to minimize weight, I cut the steel plate down to the width of the trucks. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMPImeNuMihsgOTmF9L2JcBY1bPWqzEYWDs4yyGFpUEpxaCd97jj8-N4kNqHPw0zBmkPAYAHFndItt5tZq7HNJrBHADyf8PzKLtrcSh3OhWkWzAnNwgP2ONAdOU8rw4EPZy-dzuMFveuE/s1600/2013-04-29+00.15.41.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMPImeNuMihsgOTmF9L2JcBY1bPWqzEYWDs4yyGFpUEpxaCd97jj8-N4kNqHPw0zBmkPAYAHFndItt5tZq7HNJrBHADyf8PzKLtrcSh3OhWkWzAnNwgP2ONAdOU8rw4EPZy-dzuMFveuE/s640/2013-04-29+00.15.41.jpg" width="640" /></a></div>
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I learned a cool new milling technique that doesn't make loud disgusting sounds. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiuomLirV3SUVx3lunAwgbWFwSFQOY2O38hvaXUivU_rJoSqT35AT1abjtdKN7DU-A9CEKE-oRFBDuADbkjA7Y79F96PiV7XrGQEW3r1xQKGdvgrPJjguihnPYDpleOIBEK-yyPxZs8gPc/s1600/2013-04-29+02.06.20+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiuomLirV3SUVx3lunAwgbWFwSFQOY2O38hvaXUivU_rJoSqT35AT1abjtdKN7DU-A9CEKE-oRFBDuADbkjA7Y79F96PiV7XrGQEW3r1xQKGdvgrPJjguihnPYDpleOIBEK-yyPxZs8gPc/s640/2013-04-29+02.06.20+-+Copy.jpg" width="640" /></a></div>
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Drilled and <strike>countersinked</strike> countersunk holes.</div>
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<a href="http://1.bp.blogspot.com/-Mk2HWbjpNSY/UYckpoKZqYI/AAAAAAAABEw/gc4Ww5DriJY/s1600/2013-04-29+02.14.39+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-Mk2HWbjpNSY/UYckpoKZqYI/AAAAAAAABEw/gc4Ww5DriJY/s640/2013-04-29+02.14.39+-+Copy.jpg" width="640" /></a></div>
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<a href="http://1.bp.blogspot.com/-eK_0JNKyRqM/UYckvHt2N5I/AAAAAAAABE4/3_dds7N4KDw/s1600/2013-04-29+02.14.51+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-eK_0JNKyRqM/UYckvHt2N5I/AAAAAAAABE4/3_dds7N4KDw/s640/2013-04-29+02.14.51+-+Copy.jpg" width="640" /></a></div>
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Then made them look all shiny with the angle grinder paddle wheel. </div>
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<a href="http://3.bp.blogspot.com/-iEvlp3Qv4E8/UYck0RyZpUI/AAAAAAAABFA/-uErtxV-Rbs/s1600/2013-04-29+02.15.52+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://3.bp.blogspot.com/-iEvlp3Qv4E8/UYck0RyZpUI/AAAAAAAABFA/-uErtxV-Rbs/s640/2013-04-29+02.15.52+-+Copy.jpg" width="640" /></a></div>
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<a href="http://4.bp.blogspot.com/-gXpED2AEASI/UYck53peWSI/AAAAAAAABFI/h1dt8WfQqdg/s1600/2013-04-29+02.33.17+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://4.bp.blogspot.com/-gXpED2AEASI/UYck53peWSI/AAAAAAAABFI/h1dt8WfQqdg/s640/2013-04-29+02.33.17+-+Copy.jpg" width="640" /></a></div>
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I pretty much just eye-balled it to get it centered with the rings (problem was, the rings weren't square). </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTDrs5pUsz2WwToAzQw9DaCVVzlrmjHm-f7YnUfDzPu-8ZPgMcX215sNIyQHDmAMJnNt2i9ZePy1WjIDXFH3CpWmMC5u6PNq5a9ZYbjDEBlOC704Yb_ewOYQzJC4T_lTUCV716d3dzpfM/s1600/2013-04-29+02.37.02+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiTDrs5pUsz2WwToAzQw9DaCVVzlrmjHm-f7YnUfDzPu-8ZPgMcX215sNIyQHDmAMJnNt2i9ZePy1WjIDXFH3CpWmMC5u6PNq5a9ZYbjDEBlOC704Yb_ewOYQzJC4T_lTUCV716d3dzpfM/s640/2013-04-29+02.37.02+-+Copy.jpg" width="640" /></a></div>
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Tack welds. </div>
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<a href="http://4.bp.blogspot.com/-vVzoNVvy9PQ/UYclELBnd4I/AAAAAAAABFY/28cmI7nHZBo/s1600/2013-04-29+02.37.15+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://4.bp.blogspot.com/-vVzoNVvy9PQ/UYclELBnd4I/AAAAAAAABFY/28cmI7nHZBo/s640/2013-04-29+02.37.15+-+Copy.jpg" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhE2RXt9d7zrfJQG86e9ZDyLWExaOn_M_JhTp5My_jYt6VWdpelpotVx0cFQ1NxmC-U2md00UU6ypEfXCgpcCuRGRZLCvzJ1502-Hs9SJq-uSp90kpEnIh5CbSNSEABjykBEhZ7wU7bu10/s1600/2013-04-29+02.48.47+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhE2RXt9d7zrfJQG86e9ZDyLWExaOn_M_JhTp5My_jYt6VWdpelpotVx0cFQ1NxmC-U2md00UU6ypEfXCgpcCuRGRZLCvzJ1502-Hs9SJq-uSp90kpEnIh5CbSNSEABjykBEhZ7wU7bu10/s640/2013-04-29+02.48.47+-+Copy.jpg" width="640" /></a></div>
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More MIG welding...</div>
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<a href="http://4.bp.blogspot.com/-xMXcLCt3wtU/UYclJD054MI/AAAAAAAABFg/PKQrVrnk6Kg/s1600/2013-04-29+02.39.49+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://4.bp.blogspot.com/-xMXcLCt3wtU/UYclJD054MI/AAAAAAAABFg/PKQrVrnk6Kg/s640/2013-04-29+02.39.49+-+Copy.jpg" width="640" /></a></div>
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Pretty colors :) and well, the right side of that weld looks alright. </div>
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<a href="http://3.bp.blogspot.com/-DM_grv9Ylzw/UYclOmE483I/AAAAAAAABFo/8MKFeJTzj5o/s1600/2013-04-29+02.48.36+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://3.bp.blogspot.com/-DM_grv9Ylzw/UYclOmE483I/AAAAAAAABFo/8MKFeJTzj5o/s640/2013-04-29+02.48.36+-+Copy.jpg" width="640" /></a></div>
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<a href="http://totallyharmless.blogspot.com/">Nick</a> suggested I take a torch to the frame and make the hole thing have pretty colors. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZjuK1CCMK1kKON78mnzKG9M5VgUHdQtIkx1XPqHRX242UJaLp6Djf1JasjQkeOJapNuQxMz-3MdkboPKLzGcEudygD2ORSXfUyGJJrjAKKO0HM_n9urZS3s6R_WrfVGJ34GsSsaEbxvU/s1600/2013-04-29+03.12.40.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgZjuK1CCMK1kKON78mnzKG9M5VgUHdQtIkx1XPqHRX242UJaLp6Djf1JasjQkeOJapNuQxMz-3MdkboPKLzGcEudygD2ORSXfUyGJJrjAKKO0HM_n9urZS3s6R_WrfVGJ34GsSsaEbxvU/s640/2013-04-29+03.12.40.jpg" width="640" /></a><br />
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Looks like a wrench on wheels. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRC2kixNY1o2T56Cp15KMsmiCgrdG9-mXDRuZHY1eVaSaYDTRic5AmzVnSwFTmOIoXBPjWvhc8iwobOa0i4bTJ1F7fboYrwLKKXUAPIS5YwHkNeuNxWPl0vlrCmLawj0phpSZzcqtDmTY/s1600/2013-04-29+03.12.48+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjRC2kixNY1o2T56Cp15KMsmiCgrdG9-mXDRuZHY1eVaSaYDTRic5AmzVnSwFTmOIoXBPjWvhc8iwobOa0i4bTJ1F7fboYrwLKKXUAPIS5YwHkNeuNxWPl0vlrCmLawj0phpSZzcqtDmTY/s640/2013-04-29+03.12.48+-+Copy.jpg" width="640" /></a></div>
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<a href="http://4.bp.blogspot.com/-U0ZDIbXqzjI/UYcltSXS5sI/AAAAAAAABGY/OxrH1TUfM9Y/s1600/2013-04-29+03.13.37+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://4.bp.blogspot.com/-U0ZDIbXqzjI/UYcltSXS5sI/AAAAAAAABGY/OxrH1TUfM9Y/s640/2013-04-29+03.13.37+-+Copy.jpg" width="640" /></a></div>
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They kind of glow in the dark. They might need more light to work well though. </div>
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<a href="http://2.bp.blogspot.com/-0PCNqdO7Lbg/UYcl3j1vODI/AAAAAAAABGo/R3-D5HvPDVo/s1600/2013-04-29+03.24.55+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://2.bp.blogspot.com/-0PCNqdO7Lbg/UYcl3j1vODI/AAAAAAAABGo/R3-D5HvPDVo/s640/2013-04-29+03.24.55+-+Copy.jpg" width="640" /></a></div>
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I put the hacksaw blade through the rings to saw off the inside wrench plate. </div>
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<a href="http://1.bp.blogspot.com/-W1IynvtWegw/UYcl9SYSUWI/AAAAAAAABGw/0iqIlCl4FQI/s1600/2013-04-29+04.08.20+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-W1IynvtWegw/UYcl9SYSUWI/AAAAAAAABGw/0iqIlCl4FQI/s640/2013-04-29+04.08.20+-+Copy.jpg" width="640" /></a></div>
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I welded the hammered out half-rings in place to give it more structure length wise. However, it turns out that the steel rings aren't quite strong enough to support 75 kg. It bent too much (past its elastic region) causing permanent deformation. </div>
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<a href="http://3.bp.blogspot.com/-1V7hwsmCL_Q/UYcmD-WrTBI/AAAAAAAABG4/aQOeXeawi3M/s1600/2013-04-29+05.32.50+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://3.bp.blogspot.com/-1V7hwsmCL_Q/UYcmD-WrTBI/AAAAAAAABG4/aQOeXeawi3M/s640/2013-04-29+05.32.50+-+Copy.jpg" width="640" /></a></div>
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Walking back to East Campus Monday morning at 0500... good thing my classes don't start until 1400.</div>
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I figured out a way to stiffen up the board with two 0.375" diameter steel rods and the left over plates from the wrench. I milled the edges of the support truck plates to make them square. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCfwWOSR-ULFLxgd9HLS_xmsU2Lqtl0la64Pvfb34aq9leZEc-MehwElWlgOoNNYWUmag-rab5Ih7I3oa2N7GdGZ2ZEzfr1fc_VQjQhDbxxOWLp8Y0xgdZlfS7cMFmK1k-8JB8MXFvwF0/s1600/2013-05-03+18.35.44+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCfwWOSR-ULFLxgd9HLS_xmsU2Lqtl0la64Pvfb34aq9leZEc-MehwElWlgOoNNYWUmag-rab5Ih7I3oa2N7GdGZ2ZEzfr1fc_VQjQhDbxxOWLp8Y0xgdZlfS7cMFmK1k-8JB8MXFvwF0/s640/2013-05-03+18.35.44+-+Copy.jpg" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3U9A1c6Gj61kOn7lb2e0G_ROQRvPffpJuFkp8s1TmN87iLnVNkvjPLUszLSQXPV2ZXDo8zDekuQt7HMFXIbRZOiF0lrXayWT2PD1CCQEmwBahZJ_TLJWdug3DKd2Ui6C-bzqNrAjrdkY/s1600/2013-05-03+19.13.33+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3U9A1c6Gj61kOn7lb2e0G_ROQRvPffpJuFkp8s1TmN87iLnVNkvjPLUszLSQXPV2ZXDo8zDekuQt7HMFXIbRZOiF0lrXayWT2PD1CCQEmwBahZJ_TLJWdug3DKd2Ui6C-bzqNrAjrdkY/s640/2013-05-03+19.13.33+-+Copy.jpg" width="640" /></a></div>
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Then made them shiny with the angle grinder paddle wheel. I like making things shiny :P.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkOTE93uEIZEwIBflS0KkBNUl0XuAFRieuDnNOYLO-68tJOGQn6DFU9gXKu0k-RK-g6PleYvRUfItiU_mGoRmNa5LuGw9i0-3CRCzdZiOEUFxNnqsGzzErlzB-XpAuB6o4yuLqs_yVDvU/s1600/2013-05-03+19.30.21+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhkOTE93uEIZEwIBflS0KkBNUl0XuAFRieuDnNOYLO-68tJOGQn6DFU9gXKu0k-RK-g6PleYvRUfItiU_mGoRmNa5LuGw9i0-3CRCzdZiOEUFxNnqsGzzErlzB-XpAuB6o4yuLqs_yVDvU/s640/2013-05-03+19.30.21+-+Copy.jpg" width="640" /></a></div>
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I cut the steel rods to the right length so I wouldn't have to worry about getting the steel plates a certain distance apart while in the welding area. The steel plates were plenty long so I could drill the truck holes after the whole assembly was welded (again using the mill to ensure the truck holes lined up correctly). </div>
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<a href="http://4.bp.blogspot.com/-11BepI20o8o/UYcmt4TMV0I/AAAAAAAABH4/4Brdw5ai0vY/s1600/2013-05-03+20.08.47+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://4.bp.blogspot.com/-11BepI20o8o/UYcmt4TMV0I/AAAAAAAABH4/4Brdw5ai0vY/s640/2013-05-03+20.08.47+-+Copy.jpg" width="640" /></a></div>
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<a href="http://4.bp.blogspot.com/-zOTf7kcZSXo/UYcmzPGQZiI/AAAAAAAABIA/D_lvcc6vgCc/s1600/2013-05-03+20.09.22+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://4.bp.blogspot.com/-zOTf7kcZSXo/UYcmzPGQZiI/AAAAAAAABIA/D_lvcc6vgCc/s640/2013-05-03+20.09.22+-+Copy.jpg" width="640" /></a></div>
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I tried TIG welding the top, but its hard... and quite frustrating. The Tungsten tip has to be sharp and pointy otherwise the "electron flame" spreads out too much. Every time the tip touches the metal, it gets dull...</div>
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<a href="http://4.bp.blogspot.com/-gxUymFB0vcE/UYcm9VvRuWI/AAAAAAAABIQ/6yYPb2_By0k/s1600/2013-05-03+20.09.45+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://4.bp.blogspot.com/-gxUymFB0vcE/UYcm9VvRuWI/AAAAAAAABIQ/6yYPb2_By0k/s640/2013-05-03+20.09.45+-+Copy.jpg" width="640" /></a></div>
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This should be plenty strong...</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimxMyBFvbXd5VUfzXdd2bqJfvksNwovAayybDRPUUD8fO5_VkMNcadgdnT_rZmoSamyMrPzJeUTJo5r8HaiHaiTc_IPiphoI14hozdGCbUkUFJDz3oFAdqx5KmDPXIjuurabi9XwWN4Xg/s1600/2013-05-04+15.46.02+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEimxMyBFvbXd5VUfzXdd2bqJfvksNwovAayybDRPUUD8fO5_VkMNcadgdnT_rZmoSamyMrPzJeUTJo5r8HaiHaiTc_IPiphoI14hozdGCbUkUFJDz3oFAdqx5KmDPXIjuurabi9XwWN4Xg/s640/2013-05-04+15.46.02+-+Copy.jpg" width="640" /></a></div>
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The grinder makes welds and extraneous shards of steel look pretty (also lots of noise and flying bits of hot steel).<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJWjVCRXrXsUx8cD_EuBFjZz0YfoIb8qTKGDadLXn3KVZQ59czAsGgFkep93aaQGg1kO7yWMMavjTDFZn6WxGlvOhXzslefeCMxMsIrLOq_AR3r2lkqIetCKU9kWugaSi2zS6xz-khvOg/s1600/2013-05-04+16.02.29.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgJWjVCRXrXsUx8cD_EuBFjZz0YfoIb8qTKGDadLXn3KVZQ59czAsGgFkep93aaQGg1kO7yWMMavjTDFZn6WxGlvOhXzslefeCMxMsIrLOq_AR3r2lkqIetCKU9kWugaSi2zS6xz-khvOg/s640/2013-05-04+16.02.29.jpg" width="640" /></a></div>
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I learned a lesson with this. The grinder can grind away a lot of material. Wouldn't want to waste an angle grinder wheel when it could be done on the <strike>infinite</strike> nearly infinite grinder rock. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgev_bzafoW1_zjnAwCbc2mIbVqMIW4frBZR1Dz35URv0bI6YuWnieS50Oh37fakTuaWTdICfc6TMA7UkJUGYAY-PajeiP_kpAYwedMAP265uaWFAeyINOoyEy-skew_QOEJBBFwOCs2sE/s1600/2013-05-04+16.02.20+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgev_bzafoW1_zjnAwCbc2mIbVqMIW4frBZR1Dz35URv0bI6YuWnieS50Oh37fakTuaWTdICfc6TMA7UkJUGYAY-PajeiP_kpAYwedMAP265uaWFAeyINOoyEy-skew_QOEJBBFwOCs2sE/s640/2013-05-04+16.02.20+-+Copy.jpg" width="640" /></a></div>
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To give the board a sense of front and back, I made one end concave with a little tail (back end). </div>
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<a href="http://1.bp.blogspot.com/-BduPKyEV8CU/UYcydA4Bu-I/AAAAAAAABNg/-bIpLZR_US8/s1600/2013-05-04+16.02.14+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-BduPKyEV8CU/UYcydA4Bu-I/AAAAAAAABNg/-bIpLZR_US8/s640/2013-05-04+16.02.14+-+Copy.jpg" width="640" /></a></div>
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I tried welding every joint in the middle in an attempt to stiffen the structure, but it still had problems with bending. The new assembly with 3/8" rods should do the trick. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCwrCwXzXTC2WyuPJW93NKju2rI1p995eF0qH_nSXaLOtZlR3Px3jRWkt6Vg4vk7lGSqzE0_P1cXUIU956hmEzOQlrKcwGErqt16hrxGMhO9Dlb0ia9D-VM-1n4Cb9wNePpzDXg168XS8/s1600/2013-05-04+19.45.48.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgCwrCwXzXTC2WyuPJW93NKju2rI1p995eF0qH_nSXaLOtZlR3Px3jRWkt6Vg4vk7lGSqzE0_P1cXUIU956hmEzOQlrKcwGErqt16hrxGMhO9Dlb0ia9D-VM-1n4Cb9wNePpzDXg168XS8/s640/2013-05-04+19.45.48.jpg" width="640" /></a></div>
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The welds looked like this after an hour of angle grinding with the paddle wheel. </div>
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<a href="http://2.bp.blogspot.com/-2KUEmIuY2pk/UYcn8Wx6B-I/AAAAAAAABJw/NvolKri669o/s1600/2013-05-04+19.45.57.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://2.bp.blogspot.com/-2KUEmIuY2pk/UYcn8Wx6B-I/AAAAAAAABJw/NvolKri669o/s640/2013-05-04+19.45.57.jpg" width="640" /></a></div>
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I used a brass wire brush drill bit to clean up the surfaces I didn't weld on in preparation for primer. However, I kind of like this shiny look. I may just paint it with a clear coat to protect it from rusting but still show the brass finish.</div>
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<a href="http://4.bp.blogspot.com/-vxvKXb4pTaE/UYcoMAtdYfI/AAAAAAAABKI/uVTqYcsP4mg/s1600/2013-05-04+22.24.18.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://4.bp.blogspot.com/-vxvKXb4pTaE/UYcoMAtdYfI/AAAAAAAABKI/uVTqYcsP4mg/s640/2013-05-04+22.24.18.jpg" width="640" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilL-8Qgk5M5j9TkpbRnOYtcbaJg0kXJp9O_5btzzlUAF3NOhgiCDgSgY90Zq8Gr2JrfjEE5QszAoFAmBeLUYsum8gh5_kHD13eDZSBSMVJZGrkZA4-KBwvb_SDBMRno2Z-QcnCXG1dUVw/s1600/2013-05-04+22.24.12.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilL-8Qgk5M5j9TkpbRnOYtcbaJg0kXJp9O_5btzzlUAF3NOhgiCDgSgY90Zq8Gr2JrfjEE5QszAoFAmBeLUYsum8gh5_kHD13eDZSBSMVJZGrkZA4-KBwvb_SDBMRno2Z-QcnCXG1dUVw/s640/2013-05-04+22.24.12.jpg" width="640" /></a></div>
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I drilled the truck holes on the mill and did more angle grinding. </div>
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<a href="http://4.bp.blogspot.com/-NCrO-KxD0_g/UYcobgHf1UI/AAAAAAAABKg/avMatPXo4d0/s1600/2013-05-04+22.25.00.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://4.bp.blogspot.com/-NCrO-KxD0_g/UYcobgHf1UI/AAAAAAAABKg/avMatPXo4d0/s640/2013-05-04+22.25.00.jpg" width="640" /></a></div>
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I used the end mill to extrude cylindrical cut-aways in the welds to make room for the spacers. I learned quite a bit about milling steel. <a href="http://wattsdottime.blogspot.com/">Julian</a> explained that it's better to make larger chip sizes, because steel work hardens. Also, depending on how the part is clamped or if there is slop in the table, the mill will actually move the part rather than cut the steel. </div>
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<a href="http://4.bp.blogspot.com/-YLpwLeyIqFg/UYcomJI5pgI/AAAAAAAABKw/8u3dKYehCpA/s1600/2013-05-05+00.07.39.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://4.bp.blogspot.com/-YLpwLeyIqFg/UYcomJI5pgI/AAAAAAAABKw/8u3dKYehCpA/s640/2013-05-05+00.07.39.jpg" width="640" /></a></div>
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I <strike>lathed</strike> turned eight 3/8" aluminum rod spacers on the lathe (which is now facing in the direction of the new building construction/road rather than the MITERS hallway because of the sweet new CNC mill). </div>
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<a href="http://3.bp.blogspot.com/-W4SoRFyutRs/UYcnCOpjV1I/AAAAAAAABIY/_-PLoRukilo/s1600/2013-05-03+20.45.19+-+Copy.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://3.bp.blogspot.com/-W4SoRFyutRs/UYcnCOpjV1I/AAAAAAAABIY/_-PLoRukilo/s640/2013-05-03+20.45.19+-+Copy.jpg" width="640" /></a></div>
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That's right. MITERS got a CNC Mill! :) It was donated by a very awesome and generous MIT lab. </div>
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<a href="http://3.bp.blogspot.com/-yIljWaIOcsI/UYcpKlvGa-I/AAAAAAAABLo/cDFxoqp0vpI/s1600/2013-05-05+03.46.14.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://3.bp.blogspot.com/-yIljWaIOcsI/UYcpKlvGa-I/AAAAAAAABLo/cDFxoqp0vpI/s640/2013-05-05+03.46.14.jpg" width="640" /></a></div>
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Anyway... pretty pictures. </div>
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<a href="http://2.bp.blogspot.com/-NCwz9AaH_P0/UYco1qJfKqI/AAAAAAAABLI/N-e9fwbwqLY/s1600/2013-05-05+03.44.53.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://2.bp.blogspot.com/-NCwz9AaH_P0/UYco1qJfKqI/AAAAAAAABLI/N-e9fwbwqLY/s640/2013-05-05+03.44.53.jpg" width="640" /></a></div>
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The deck makes a cool shadow. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhuko7PspbXH68MbL2gVyuOKQFUulWR_EiaI-QaC2HYl47qMrgGZT9AaKKAjVRBNz2qqt8si50mFJB67XQN93Ze9-qaSFrlzkcHjwdy2wDCKZBB9DwZQdKdoLGGSVNaMBdcHYaRfltpYg/s1600/2013-05-05+03.45.43.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjhuko7PspbXH68MbL2gVyuOKQFUulWR_EiaI-QaC2HYl47qMrgGZT9AaKKAjVRBNz2qqt8si50mFJB67XQN93Ze9-qaSFrlzkcHjwdy2wDCKZBB9DwZQdKdoLGGSVNaMBdcHYaRfltpYg/s640/2013-05-05+03.45.43.jpg" width="478" /></a></div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4NkoJ1yySebciHhuo0CAADtOtj9FzOYCKqy5dd0vzKbT4mW0rfC62GxnJjc1tnQb1Z-gXlZFzSkClf4df_vH_Rtdg_C9-zRu_96ha7J5B8sZ8QFWwlZnYqjkS66jNDqDPNwtxq0D_g3A/s1600/2013-05-05+03.45.18.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4NkoJ1yySebciHhuo0CAADtOtj9FzOYCKqy5dd0vzKbT4mW0rfC62GxnJjc1tnQb1Z-gXlZFzSkClf4df_vH_Rtdg_C9-zRu_96ha7J5B8sZ8QFWwlZnYqjkS66jNDqDPNwtxq0D_g3A/s640/2013-05-05+03.45.18.jpg" width="478" /></a></div>
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<a href="http://4.bp.blogspot.com/-8Pujrkzs2x0/UYcxYlz-X0I/AAAAAAAABNM/ZmLPMzd-1Nc/s1600/2013-05-05+03.43.35.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://4.bp.blogspot.com/-8Pujrkzs2x0/UYcxYlz-X0I/AAAAAAAABNM/ZmLPMzd-1Nc/s640/2013-05-05+03.43.35.jpg" width="640" /></a></div>
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Which Was What We Wanted...</div>
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Jaguar Kristellerhttp://www.blogger.com/profile/08428337775851273522noreply@blogger.com5tag:blogger.com,1999:blog-2823741957408378785.post-19431328587408335272013-04-21T20:49:00.000-04:002013-05-08T21:25:36.183-04:00Early Morning Waxing and Waning PhotographyBy "Early Morning" I mean 0300 to 0600. Eric, a really awesome programmer on my hall, and I didn't feel like sleeping. Instead, we started carving the large pieces of wax another one of our hall members crufted from Reuse awhile back. Eric had a nice camera and some color filters of various shades. We played around with them and actually got some really interesting pictures. Here is a slideshow of our doodles.<br />
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Some of these photos would make a great desktop background!</div>
<br />Jaguar Kristellerhttp://www.blogger.com/profile/08428337775851273522noreply@blogger.com0tag:blogger.com,1999:blog-2823741957408378785.post-88034998224651545282013-04-21T09:04:00.005-04:002013-05-06T04:15:51.808-04:00First All-Nighter at MITERS: Casting the Urethane Wheel<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAVd44G6_HB100AscB44sy0fGGmVQtMtZQ1QaxSKd9uh1SRotrmErLi85tDAeKKSWkFVbq_26rHEGqtHMLIabFOQXP9Us3JF77MBI7WbAC1TlvXgo5Nh5mfoAsX1pDH_OqOun2J8oz37c/s1600/2013-02-04+05.05.12.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em; text-align: center;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAVd44G6_HB100AscB44sy0fGGmVQtMtZQ1QaxSKd9uh1SRotrmErLi85tDAeKKSWkFVbq_26rHEGqtHMLIabFOQXP9Us3JF77MBI7WbAC1TlvXgo5Nh5mfoAsX1pDH_OqOun2J8oz37c/s640/2013-02-04+05.05.12.jpg" width="640" /></a><br />
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I've been procrastinating the molding of the orbit wheel in favor of machining for too long now. I need at least 24 hours for the mold to set. Starting three days before TechFair.<br />
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I poured a test mold before pouring the real mold to ensure the urethane had a good hardness and would stick to the metal. I was kind of worried about how well the urethane would grip to the small water jetted rim pieces. The test mold will also give me some experience when it comes time to do the final mold.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjohvQ6A7jRevHGdguxv_IcojJ-pxC0ZFC2EyAbGcJu4Adpdss0Zl1LQ5wddueEz9TKCcdn2utNqNxBJK-ut5uR6e4KHB1naMDrEdRl4cH6m0yu8FuCuuW4uxL5ccIYrtIjYIkIWXykdBw/s1600/2013-02-03+04.03.07+HDR.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjohvQ6A7jRevHGdguxv_IcojJ-pxC0ZFC2EyAbGcJu4Adpdss0Zl1LQ5wddueEz9TKCcdn2utNqNxBJK-ut5uR6e4KHB1naMDrEdRl4cH6m0yu8FuCuuW4uxL5ccIYrtIjYIkIWXykdBw/s640/2013-02-03+04.03.07+HDR.jpg" width="640" /></a></div>
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The test mold was a success. There are some visible air bubbles trapped inside, but it still has a good durability/hardness (shore). It also sticks to the metal pieces well, so I won't have a problem with it gripping on the wheel rims. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivf_ZFfCqFr-uCJJBwUXEYoT9yQ_2kJOZdeZ0_NohMoOF31YavPBvIcss1gGxYbnyE8PtiO3-jnI_55xrU59zG9MNlyxp1znOB6fy8DGFZuypKXbc7sZ7swHPk9jMpDueUCeKZpBV9pY4/s1600/2013-02-03+04.09.16.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivf_ZFfCqFr-uCJJBwUXEYoT9yQ_2kJOZdeZ0_NohMoOF31YavPBvIcss1gGxYbnyE8PtiO3-jnI_55xrU59zG9MNlyxp1znOB6fy8DGFZuypKXbc7sZ7swHPk9jMpDueUCeKZpBV9pY4/s640/2013-02-03+04.09.16.jpg" width="640" /></a></div>
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Now for the real mold. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhq3erd4sNJfmO0kh9jQR6RLZBSEggfXpTr3FA17YD02HfrO3BqIulbOH-LrPyfpz2hGNpfdIy9JOPCZ-G5LGHqET0kj6mi6GTJQWRqS7-hdofFLwADz4DVAgizbqaxrRzThFNNzuG-1BQ/s1600/2013-02-03+05.08.08.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhq3erd4sNJfmO0kh9jQR6RLZBSEggfXpTr3FA17YD02HfrO3BqIulbOH-LrPyfpz2hGNpfdIy9JOPCZ-G5LGHqET0kj6mi6GTJQWRqS7-hdofFLwADz4DVAgizbqaxrRzThFNNzuG-1BQ/s640/2013-02-03+05.08.08.jpg" width="640" /></a></div>
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I did some calculations and got a volume number, but there weren't any graduated cylinders at MITERS to measure out the correct volume. So, I ran across the street to a gas station and bought a seven ounce fruit cup which Kramnik gladly ate. Once I had my form of measurement, I could pour out the correct proportions of the A and B liquids.<br />
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<a href="http://1.bp.blogspot.com/-Y3Vt9YkZPWY/UVcdddOCSsI/AAAAAAAAAuA/VCN-gKgHfaQ/s1600/2013-02-03+06.00.19.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-Y3Vt9YkZPWY/UVcdddOCSsI/AAAAAAAAAuA/VCN-gKgHfaQ/s640/2013-02-03+06.00.19.jpg" width="640" /></a></div>
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Ready to pour. (I put tape around the sides to prevent spills just in case I over estimated with my math). </div>
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<a href="http://3.bp.blogspot.com/-KZ5shLgp8h8/UVcdd19742I/AAAAAAAAAuI/kdwCYGpEFmU/s1600/2013-02-03+06.14.38.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://3.bp.blogspot.com/-KZ5shLgp8h8/UVcdd19742I/AAAAAAAAAuI/kdwCYGpEFmU/s640/2013-02-03+06.14.38.jpg" width="640" /></a></div>
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Pouring the urethane had some specific "destructions" to ensure safety and a strong mold. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjs-8cAZMGZfkyhIRRliWhx3Uid59_ZP3jMXnY8rs__oLU4TB8EEuLhRxnUXg9ODkzv4RfOXxC9UA_AzaDIxcK49Y4Fsjh1fma-UEPeTuRV_drvgK89e_I-19DwjuAYTGF2_m2J88uYlJU/s1600/2013-02-03+06.57.59.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjs-8cAZMGZfkyhIRRliWhx3Uid59_ZP3jMXnY8rs__oLU4TB8EEuLhRxnUXg9ODkzv4RfOXxC9UA_AzaDIxcK49Y4Fsjh1fma-UEPeTuRV_drvgK89e_I-19DwjuAYTGF2_m2J88uYlJU/s640/2013-02-03+06.57.59.jpg" width="640" /></a></div>
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I tried pouring the urethane through one of the rim holes to let the urethane seep in and fill the mold without creating any air bubbles. However, the pot life of Econ 80 Urethane Rubber is only 13 minutes. So I poured it around the top when it started thickening, and put it on a shaker plate. Now all it needs is time. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEgkQx37iG48XYfr3Hl8v8fwobu9j0m4krDh2W5uZDL5NyGJbT01k4KLc3xyQnw-sNxlj4bVKkF4BncvrjjJAKAN0GRrB0Wf3JhyphenhyphengSxrSs_n4r3XVGjH7Dt_9WzbXxlmsUugnsoYYwHww/s1600/2013-02-03+07.26.16+HDR.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgEgkQx37iG48XYfr3Hl8v8fwobu9j0m4krDh2W5uZDL5NyGJbT01k4KLc3xyQnw-sNxlj4bVKkF4BncvrjjJAKAN0GRrB0Wf3JhyphenhyphengSxrSs_n4r3XVGjH7Dt_9WzbXxlmsUugnsoYYwHww/s640/2013-02-03+07.26.16+HDR.jpg" width="640" /></a></div>
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Walking to East Campus in the snow after a long night's work. (It's about 0730 the day before TechFair). </div>
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<a href="http://4.bp.blogspot.com/-BP6nUm8JUAg/UVcdetNV3VI/AAAAAAAAAuc/KYiUn7K7liU/s1600/2013-02-03+07.37.14+HDR.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="640" src="http://4.bp.blogspot.com/-BP6nUm8JUAg/UVcdetNV3VI/AAAAAAAAAuc/KYiUn7K7liU/s640/2013-02-03+07.37.14+HDR.jpg" width="478" /></a></div>
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Zzzzzzzzz...<br />
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After a long 20 hours of sitting in the mold, the urethane wheel was ready to come out. </div>
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<a href="http://4.bp.blogspot.com/-pJGSWzRIBoU/UVcdgMREtMI/AAAAAAAAAvA/I4U2R3Nfw6w/s1600/2013-02-04+04.10.10+HDR.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://4.bp.blogspot.com/-pJGSWzRIBoU/UVcdgMREtMI/AAAAAAAAAvA/I4U2R3Nfw6w/s640/2013-02-04+04.10.10+HDR.jpg" width="640" /></a></div>
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The 80A urethane rubber is pretty durable especially after putting up with prying off the first half with flat head screw drivers. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAVd44G6_HB100AscB44sy0fGGmVQtMtZQ1QaxSKd9uh1SRotrmErLi85tDAeKKSWkFVbq_26rHEGqtHMLIabFOQXP9Us3JF77MBI7WbAC1TlvXgo5Nh5mfoAsX1pDH_OqOun2J8oz37c/s1600/2013-02-04+05.05.12.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAVd44G6_HB100AscB44sy0fGGmVQtMtZQ1QaxSKd9uh1SRotrmErLi85tDAeKKSWkFVbq_26rHEGqtHMLIabFOQXP9Us3JF77MBI7WbAC1TlvXgo5Nh5mfoAsX1pDH_OqOun2J8oz37c/s640/2013-02-04+05.05.12.jpg" width="640" /></a></div>
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Removing the top half of the mold was relatively easy. I designed this feature in my CAD. However, the bottom half is a different story. I was hoping the urethane wouldn't stick to the plastic as well, but it did.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4hVH842h0EoSCJAB62kr7Mke1LmQj3rfz-wDQjZJQevAy5kxh8aoelZ9Y7cukcqP_wG4JEVBGVHQnyXvIAxG9y8SoboKg4lquD8_qzLiQop7nnVc6bgXu5TmlML9JZK3QuwOrF6H0RQk/s1600/2013-02-04+05.44.45+HDR.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh4hVH842h0EoSCJAB62kr7Mke1LmQj3rfz-wDQjZJQevAy5kxh8aoelZ9Y7cukcqP_wG4JEVBGVHQnyXvIAxG9y8SoboKg4lquD8_qzLiQop7nnVc6bgXu5TmlML9JZK3QuwOrF6H0RQk/s640/2013-02-04+05.44.45+HDR.jpg" width="640" /></a></div>
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Unfortunately, I had to destroy my 3D printed mold (which Charles probably won't be too happy about). With a few handy pliers, flat screw drivers, and persistence, I managed to break apart the mold (one piece of plastic at a time). This might be preventable in the future if I get some more chemicals from Smooth-On. </div>
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<a href="http://2.bp.blogspot.com/-1LKxq2n1qUA/UVcdh9gYddI/AAAAAAAAAvw/gqE2cAmtcqQ/s1600/2013-02-04+07.13.35+HDR.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://2.bp.blogspot.com/-1LKxq2n1qUA/UVcdh9gYddI/AAAAAAAAAvw/gqE2cAmtcqQ/s640/2013-02-04+07.13.35+HDR.jpg" width="640" /></a></div>
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I cleaned up the edges with a belt sander. The urethane rubber was bumpy on the top side, so I just sanded it all the way down to the aluminum to get a nice finish. </div>
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<a href="http://4.bp.blogspot.com/-fM58xgKjXvg/UVcdiKwz8lI/AAAAAAAAAv4/guhYIt0X9yk/s1600/2013-02-04+07.13.54+HDR.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://4.bp.blogspot.com/-fM58xgKjXvg/UVcdiKwz8lI/AAAAAAAAAv4/guhYIt0X9yk/s640/2013-02-04+07.13.54+HDR.jpg" width="640" /></a></div>
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The 3D printed cast left a little 3D printed-like texture on the urethane wheel. This will probably wear off after repeated use, but it looks pretty cool. <br />
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Here are some pretty pictures of the CADed urethane wheel:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfQf6_Pg9Baz_ZJ8EswITqz65_2HYxJhJeJSs-kfg8XxTz9mOiyZWvfnKWXYLd4G0vmQQaSbS3sRXfOAIXd-gQIoXFZCeaDgzCqtJGv1y7MHAgotPBg_Sufi5s9yvtGmbTeoWSb0pQsAU/s1600/rim_assembly4.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="456" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfQf6_Pg9Baz_ZJ8EswITqz65_2HYxJhJeJSs-kfg8XxTz9mOiyZWvfnKWXYLd4G0vmQQaSbS3sRXfOAIXd-gQIoXFZCeaDgzCqtJGv1y7MHAgotPBg_Sufi5s9yvtGmbTeoWSb0pQsAU/s640/rim_assembly4.png" width="640" /></a></div>
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<a href="http://4.bp.blogspot.com/-v9XCTRTESgI/UXM4UlLERwI/AAAAAAAAA5g/XcNMr6G1YP4/s1600/complete_orbit_wheel.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="546" src="http://4.bp.blogspot.com/-v9XCTRTESgI/UXM4UlLERwI/AAAAAAAAA5g/XcNMr6G1YP4/s640/complete_orbit_wheel.png" width="640" /></a></div>
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Sunshine at MITERS... What?<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhHOxTQNT8fXmisqASIZ1jBwSTNLAo-BsO3R12rL1FmUPKovGN3hXf48vDr_Q_IZH_dhNQrfdF2kg6g2K8HookQ-3YpFB2d7o5LxF41vRt4lKAinHvOpaXylMhW1QcysYewOvDdDotRdcc/s1600/2013-02-04+07.39.10+HDR.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhHOxTQNT8fXmisqASIZ1jBwSTNLAo-BsO3R12rL1FmUPKovGN3hXf48vDr_Q_IZH_dhNQrfdF2kg6g2K8HookQ-3YpFB2d7o5LxF41vRt4lKAinHvOpaXylMhW1QcysYewOvDdDotRdcc/s640/2013-02-04+07.39.10+HDR.jpg" width="640" /></a></div>
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It fits nicely around the frame, and it has enough clearance to lean without scraping the front and back plates too much. The urethane wheel was the last part to get finished. Then it was just a race against time to assemble it all before TechFair. (Notice the sunlight shining on the orbit wheel; its early in the morning).<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFCEuCvbQHWhJEX5UQ_HGeRzsMl-aordrzD26nsTrgVHQACyt7GDhQiO37njZiZ8bDo7mxG1SlEz_3XLJWe2sa8U_901YmkDReMysLe3avPogJt9LEx4_lNB2BfNY7Rb2wjR4cB4Etwew/s1600/2013-02-04+17.50.53.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgFCEuCvbQHWhJEX5UQ_HGeRzsMl-aordrzD26nsTrgVHQACyt7GDhQiO37njZiZ8bDo7mxG1SlEz_3XLJWe2sa8U_901YmkDReMysLe3avPogJt9LEx4_lNB2BfNY7Rb2wjR4cB4Etwew/s640/2013-02-04+17.50.53.jpg" width="640" /></a></div>
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Connecting all the internal wires without shorting the pack was probably the most difficult part of assembling the wheel. Especially with the adrenaline and exhaustion from working all night right before the revealing. </div>
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<a href="http://2.bp.blogspot.com/-SkzNoBI2Lhg/UVcdkW87mBI/AAAAAAAAAwk/58rQvQmKqTQ/s1600/2013-02-04+17.50.22.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="640" src="http://2.bp.blogspot.com/-SkzNoBI2Lhg/UVcdkW87mBI/AAAAAAAAAwk/58rQvQmKqTQ/s640/2013-02-04+17.50.22.jpg" width="478" /></a></div>
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After getting the battery wires and the three motor wires connected internally, the rest of the assembly was just putting in screws. </div>
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<a href="http://3.bp.blogspot.com/-JuNTYlKeezk/UVcdkMIDLhI/AAAAAAAAAws/0Sc0nD0xHCE/s1600/2013-02-04+17.49.49.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://3.bp.blogspot.com/-JuNTYlKeezk/UVcdkMIDLhI/AAAAAAAAAws/0Sc0nD0xHCE/s640/2013-02-04+17.49.49.jpg" width="640" /></a></div>
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Done! Well that's what I thought anyway. I took it for a quick test run in the MITERS hallway, and made it about 10 feet before the spur gear started slipping on the motor shaft. </div>
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I decided to take it to TechFair and fix it there.</div>
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I had to break it open again, but fortunately I managed to take out the inside plate assembly without disconnecting all the internal wires.</div>
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I took a small file to the motor shaft and made the flat better. I also added some of DGonz's red loctite to the set screw to make sure it wouldn't come loose.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMcZJ8BUpXUGlWcoqh6s_0jR3A8tIt93Y7Mr3gMT6MAImn_5gSIXg_5wPK79j9OAXRTroG-rjOVmNEkm0mxLEtx1LevS_im5nbU1nteX6bJWtq-CmFcWQr0k0ddAIZ8tAkKYWMu7RjLl8/s1600/2013-02-04+10.16.07+HDR.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMcZJ8BUpXUGlWcoqh6s_0jR3A8tIt93Y7Mr3gMT6MAImn_5gSIXg_5wPK79j9OAXRTroG-rjOVmNEkm0mxLEtx1LevS_im5nbU1nteX6bJWtq-CmFcWQr0k0ddAIZ8tAkKYWMu7RjLl8/s640/2013-02-04+10.16.07+HDR.jpg" width="640" /></a></div>
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This temporary fix worked well for the duration of TechFair. I was able to ride them around all day on one charge. <br />
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<a href="http://1.bp.blogspot.com/-G7M7lWcx09E/UVclc0NNOII/AAAAAAAAAxs/shuILhDwiWc/s1600/tech_fair1.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="640" src="http://1.bp.blogspot.com/-G7M7lWcx09E/UVclc0NNOII/AAAAAAAAAxs/shuILhDwiWc/s640/tech_fair1.jpg" width="480" /></a></div>
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TechFair was pretty fun. We had multiple electric vehicle parades (MITERS and MIT's Electric Vehicle Team). TechFair marked the end of the building process for my first Electric Orbit Wheel prototype. I've got plans for another. </div>
Jaguar Kristellerhttp://www.blogger.com/profile/08428337775851273522noreply@blogger.com1tag:blogger.com,1999:blog-2823741957408378785.post-33917933654033237302013-04-21T08:57:00.001-04:002013-05-06T04:15:51.745-04:00Tightly Packed Electronics and Machined Housing<div style="text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhc9zsK9jnTyAEWmBW0Md3y5rNmKYj4GO3J-vDma_7Zhm4f9doCvtTp5rWNc4qtV2i3crS4Zjp4ulWYEeKpC6QpOkBtc-w5SI78ChjU1H-F2SkWCKeYlCrk8KCPH7OpKg6rWqn17olsic0/s1600/2013-02-02+01.55.07+HDR.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><br /><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhc9zsK9jnTyAEWmBW0Md3y5rNmKYj4GO3J-vDma_7Zhm4f9doCvtTp5rWNc4qtV2i3crS4Zjp4ulWYEeKpC6QpOkBtc-w5SI78ChjU1H-F2SkWCKeYlCrk8KCPH7OpKg6rWqn17olsic0/s640/2013-02-02+01.55.07+HDR.jpg" width="640" /></a></div>
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After my <a href="http://www.hobbyking.com/hobbyking/store/__18170__Turnigy_Aerodrive_SK3_4250_350kv_Brushless_Outrunner_Motor.html">motors</a>, <a href="http://www.hobbyking.com/hobbyking/store/__11743__HobbyKing_Brushless_Car_ESC_60A_w_Reverse.html">motor controllers</a>, and HobbyKing <a href="http://www.hobbyking.com/hobbyking/store/__10608__Hobby_King_GT_2_2_4Ghz_2Ch_Tx_Rx.html">radio transmitter and reciever</a> came in the mail from a long and expressed journey, I could start on the electronics. I decided not to cram it all inside with the ring gear, because I may potentially get sprinkling aluminum flakes as the bearings etch away the water jetted surface. This change of plans required more machined aluminum, which I could do on the MITERS mill. </div>
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Attaching the motor. I couldn't find any small M3 screws in Stata's amazing collection of neatly organized screws, so I ordered some from McMaster (which got here the next day :P). </div>
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<a href="http://2.bp.blogspot.com/-RJ8BLnbVRsk/UVcdaF3HcHI/AAAAAAAAAss/28pF9KlYSbs/s1600/2013-02-01+21.56.08+HDR.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://2.bp.blogspot.com/-RJ8BLnbVRsk/UVcdaF3HcHI/AAAAAAAAAss/28pF9KlYSbs/s640/2013-02-01+21.56.08+HDR.jpg" width="640" /></a></div>
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I filed a flat on the motor and tightened the spur gear down. The Allen wrench is very small, so I couldn't really get it at tight as I normally like. </div>
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<a href="http://1.bp.blogspot.com/-p30s1rt37x4/UVcdWQIHUDI/AAAAAAAAArY/ueitUrSolR4/s1600/2013-01-26+22.36.24.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-p30s1rt37x4/UVcdWQIHUDI/AAAAAAAAArY/ueitUrSolR4/s640/2013-01-26+22.36.24.jpg" width="640" /></a></div>
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Motor is attached. Next all the wiring needs to get hooked up to the motor controller. To hold all the wires, I machined a small box on the mill. (I used my CADed model to figure out the dimensions of a box which<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrOwtZn77kCUc6XK_icroe4npScpgY5oBNcLEqE-9lf9Lx3wtE688glA2NaOePRfbMjHbmAyBRpKjIYzC8qtTHkEcZ409h2Mv8g-tG502pSZk0ni2dxhZEuK26t-R4y6potgL58Sc7Ms4/s1600/2013-01-29+23.10.15.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrOwtZn77kCUc6XK_icroe4npScpgY5oBNcLEqE-9lf9Lx3wtE688glA2NaOePRfbMjHbmAyBRpKjIYzC8qtTHkEcZ409h2Mv8g-tG502pSZk0ni2dxhZEuK26t-R4y6potgL58Sc7Ms4/s640/2013-01-29+23.10.15.jpg" width="640" /></a></div>
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I got some metal from the MITERS stock piles, and used the end mill to machine flat/perpendicular sides. The small blocks are 1" x 2", the middle piece is 1" x 3", and the 1/8" thick piece is 2.25" x 3" (actually first made this part 2" x 3" due to my lack of sleep). </div>
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<a href="http://3.bp.blogspot.com/-lD7KBkq9mUU/UVcdaMgVWpI/AAAAAAAAAsw/3OxX217o8oE/s1600/2013-01-30+02.10.26+HDR.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://3.bp.blogspot.com/-lD7KBkq9mUU/UVcdaMgVWpI/AAAAAAAAAsw/3OxX217o8oE/s640/2013-01-30+02.10.26+HDR.jpg" width="640" /></a></div>
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I drilled and countersunk the holes in the freshly milled pieces (as well as in the back plate). The hole on the inside is very smooth so the wire's insulation does not get cut on the frame (I used a "deburring" tool to smooth the circular edge). </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhL3c5sjaEDbeKLuEuP2gXx9rhgbyrZu50RpCkWPH_WtYW24F408gYbaEFNmMOUTpr7E-BV16YRI8YTysaTpzu84TIsvRD7s-KJyh3kWcq3Ggi579lT4ykya2EyYUzq_UnwFWPb0G-v0q0/s1600/2013-01-30+02.10.10.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhL3c5sjaEDbeKLuEuP2gXx9rhgbyrZu50RpCkWPH_WtYW24F408gYbaEFNmMOUTpr7E-BV16YRI8YTysaTpzu84TIsvRD7s-KJyh3kWcq3Ggi579lT4ykya2EyYUzq_UnwFWPb0G-v0q0/s640/2013-01-30+02.10.10.jpg" width="640" /></a><br />
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The screws I used for the orbit wheel rim were just long enough. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhc9zsK9jnTyAEWmBW0Md3y5rNmKYj4GO3J-vDma_7Zhm4f9doCvtTp5rWNc4qtV2i3crS4Zjp4ulWYEeKpC6QpOkBtc-w5SI78ChjU1H-F2SkWCKeYlCrk8KCPH7OpKg6rWqn17olsic0/s1600/2013-02-02+01.55.07+HDR.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhc9zsK9jnTyAEWmBW0Md3y5rNmKYj4GO3J-vDma_7Zhm4f9doCvtTp5rWNc4qtV2i3crS4Zjp4ulWYEeKpC6QpOkBtc-w5SI78ChjU1H-F2SkWCKeYlCrk8KCPH7OpKg6rWqn17olsic0/s640/2013-02-02+01.55.07+HDR.jpg" width="640" /></a></div>
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I used the belt sander to round off all the edges, and make smooth holes for the wires to enter the box. I managed to cram the small ESC controller into the space (without the fan). Now for all the soldering. </div>
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<a href="http://3.bp.blogspot.com/-Ic-vUEqSMBo/UVcdbC1b78I/AAAAAAAAAtI/vBF20mnTWI8/s1600/2013-02-02+23.15.23+HDR.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://3.bp.blogspot.com/-Ic-vUEqSMBo/UVcdbC1b78I/AAAAAAAAAtI/vBF20mnTWI8/s640/2013-02-02+23.15.23+HDR.jpg" width="640" /></a></div>
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I cut off the XT60 connectors and replaced them with Dean's connectors, because I found a compact Dean's connector soldered onto some bullet connectors.</div>
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After finishing all the soldering and wiring, I CADed up a rectangular rim so I could enclose the "wirey" mess. I used the IDC's laser cutter to cut the same thick acrylic I used for the battery clips. </div>
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<tr><td style="text-align: center;"><a href="http://4.bp.blogspot.com/-ozK8cKmvJug/UXPg9p7RI7I/AAAAAAAAA8E/kJ3JnA9PrfE/s1600/2013-02-04+04.02.19+HDR.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="478" src="http://4.bp.blogspot.com/-ozK8cKmvJug/UXPg9p7RI7I/AAAAAAAAA8E/kJ3JnA9PrfE/s640/2013-02-04+04.02.19+HDR.jpg" width="640" /></a></td></tr>
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<a href="http://4.bp.blogspot.com/-uAAWobuQcHg/UXPg9du8x2I/AAAAAAAAA8A/ve6XgovKuBg/s1600/2013-02-04+04.02.33.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://4.bp.blogspot.com/-uAAWobuQcHg/UXPg9du8x2I/AAAAAAAAA8A/ve6XgovKuBg/s640/2013-02-04+04.02.33.jpg" width="640" /></a></div>
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The electric orbit wheel is almost finished! All I have to do now is pour some urethane to make a wheel!</div>
Jaguar Kristellerhttp://www.blogger.com/profile/08428337775851273522noreply@blogger.com1tag:blogger.com,1999:blog-2823741957408378785.post-68703283035807735732013-04-21T08:01:00.002-04:002013-05-06T04:15:51.797-04:00Cruft Shelf<div class="separator" style="clear: both; text-align: left;">
I found a really nice piece of plywood on hall, and my closet was overflowing with closet stuff and cruft. So I decided to make shelf exclusively for crufty things. Also, since I have a loft, I have a bunch of places to attach things. Therefore, I can make the most efficient use of the space in my small room (it is actually the smallest room on hall and the only "<a href="http://kriste11er.blogspot.com/2013/02/loft-and-painting.html">double</a>"). </div>
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<a href="http://3.bp.blogspot.com/-hgdMnnB50C8/UXPSHbhzDlI/AAAAAAAAA7Y/uOGWGN1zCcc/s1600/2013-02-16+17.30.09.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://3.bp.blogspot.com/-hgdMnnB50C8/UXPSHbhzDlI/AAAAAAAAA7Y/uOGWGN1zCcc/s640/2013-02-16+17.30.09.jpg" width="640" /></a></div>
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Click to read about the very short build:</div>
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I cut up a crufted 2 x 4 beam into four 11" pieces in the <a href="http://ec.mit.edu/">East Campus</a> basement. </div>
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<a href="http://3.bp.blogspot.com/-bnw0iLG1YcQ/UXPSGc2oLQI/AAAAAAAAA68/SOl1yW9Y6FU/s1600/2013-02-16+17.07.39.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://3.bp.blogspot.com/-bnw0iLG1YcQ/UXPSGc2oLQI/AAAAAAAAA68/SOl1yW9Y6FU/s640/2013-02-16+17.07.39.jpg" width="640" /></a></div>
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Borrowed a drill from ToolComm. </div>
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<a href="http://1.bp.blogspot.com/-hnNkRSnHfYc/UXPSGEy4xMI/AAAAAAAAA60/ovXAQfYvqBU/s1600/2013-02-16+17.06.52.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-hnNkRSnHfYc/UXPSGEy4xMI/AAAAAAAAA60/ovXAQfYvqBU/s640/2013-02-16+17.06.52.jpg" width="640" /></a></div>
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It is much easier to use gravity and screw/drill down than it is to screw/drill up in a very tight space. </div>
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<a href="http://4.bp.blogspot.com/-NFtJOzbqv3Q/UXPSGOzOBSI/AAAAAAAAA64/OIAHY9Ok8Xw/s1600/2013-02-16+17.07.05.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="640" src="http://4.bp.blogspot.com/-NFtJOzbqv3Q/UXPSGOzOBSI/AAAAAAAAA64/OIAHY9Ok8Xw/s640/2013-02-16+17.07.05.jpg" width="478" /></a></div>
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I attached them to the corners of the polished plywood with the left over screws I used on the loft. </div>
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<a href="http://3.bp.blogspot.com/-qc0SNXycNEE/UXPSGjbAG6I/AAAAAAAAA7E/WYQ9coe0yDI/s1600/2013-02-16+17.29.50.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://3.bp.blogspot.com/-qc0SNXycNEE/UXPSGjbAG6I/AAAAAAAAA7E/WYQ9coe0yDI/s640/2013-02-16+17.29.50.jpg" width="640" /></a></div>
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To help with screwing/drilling the cruft shelf in place, I pre-screwed/drilled the screws half way into the loft. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiX-aPLZ0O0N-ZoaiR2csrZ_JxNovqa0lMNtE1dAJ1oG0scdd21WR1IB8KHcd95Z3Ky9FxFbREnW7ydtpotvu_F-onurJ7nlZVKjIq2C_gbrp1f5qdl8Ie1HX-nuRbJxXFsMnXEqsZrUpU/s1600/2013-02-16+17.29.58.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiX-aPLZ0O0N-ZoaiR2csrZ_JxNovqa0lMNtE1dAJ1oG0scdd21WR1IB8KHcd95Z3Ky9FxFbREnW7ydtpotvu_F-onurJ7nlZVKjIq2C_gbrp1f5qdl8Ie1HX-nuRbJxXFsMnXEqsZrUpU/s640/2013-02-16+17.29.58.jpg" width="640" /></a></div>
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Ready for crufty things :)</div>
Jaguar Kristellerhttp://www.blogger.com/profile/08428337775851273522noreply@blogger.com0tag:blogger.com,1999:blog-2823741957408378785.post-58683812271952624672013-04-21T04:34:00.002-04:002013-05-12T22:02:23.396-04:003D Printed Urethane Mold and Ring Gear<div style="text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSFTzSmMtYe2Pu62hEEWknCImrXDyjoFxFpcpRuLNkrWCYj9OC4nfj9oZPitU1oKAIoLUjFodzrvM07uZmARWu5qqIJkilTtN2EXA_u_VIouLZiDMdFZ59SbUsHpisF4hjkQ_mTxx_eDg/s1600/rim_assembly1.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="521" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSFTzSmMtYe2Pu62hEEWknCImrXDyjoFxFpcpRuLNkrWCYj9OC4nfj9oZPitU1oKAIoLUjFodzrvM07uZmARWu5qqIJkilTtN2EXA_u_VIouLZiDMdFZ59SbUsHpisF4hjkQ_mTxx_eDg/s640/rim_assembly1.png" width="640" /></a></div>
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The ring gear was the main reason I decided to make my own wheel. I couldn't find any wheels without hubs that also had a ring gear inside. So I designed a wheel rim with a bunch of water jetted aluminum rings (one being the ring gear). The ring gear was the most stubborn of the bunch. It really tested my dedication to this project. There were a few times that I ran out of ideas on how to make it. But I persisted. I was probably doing it completely wrong, but I came up with a solution that worked using Autodesk's gear generator.<br />
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First, I designed the ring which the bearings will ride on (ring bearing track) and the ridges that will keep the bearings on the bearing track (track ridges).<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZXaDrfhrqUCs0oAJZ5yner9-s5z9QYQ9TEK2lJ161xmTiJqPEECoFn9ttjt90osy5CTVA2XikCI-2URhEnwRoUBnWnehU0Gku-_u9m3foV0sojRKDR4oDIp56UmqKVTEh2GWlEvBMXK8/s1600/ring_bearing_track.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="508" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjZXaDrfhrqUCs0oAJZ5yner9-s5z9QYQ9TEK2lJ161xmTiJqPEECoFn9ttjt90osy5CTVA2XikCI-2URhEnwRoUBnWnehU0Gku-_u9m3foV0sojRKDR4oDIp56UmqKVTEh2GWlEvBMXK8/s640/ring_bearing_track.png" width="640" /></a></div>
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The elongated holes allow for the urethane to seep in and interlock with the aluminum rim. The inner diameter is 7" and the outer is 7.8" to give 0.4" for the holes and to fit in the 8" wide aluminum stock I purchased from McMaster. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhG8uX9JyoISWif-r65VirOaINlaEmLC_tPjeHfdE_zF7Hcu4C9L5dWXMC9oScc153Pgm68A5UZ5de2TARM5p1P-GGagZagtAy5oei_r3XQme-PI5GVOG5_qiK3-mKi-w6kgYsWToxfABY/s1600/track_ridge.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="508" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhG8uX9JyoISWif-r65VirOaINlaEmLC_tPjeHfdE_zF7Hcu4C9L5dWXMC9oScc153Pgm68A5UZ5de2TARM5p1P-GGagZagtAy5oei_r3XQme-PI5GVOG5_qiK3-mKi-w6kgYsWToxfABY/s640/track_ridge.png" width="640" /></a></div>
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The track ridge parts have an 6.8" inner diameter to provide a 0.1" ridge for the bearings. I decided to make this part a third of a full circle, because it will reduce the amount of aluminum waste. I can pack them tightly together in Omax Layout for the water jet. </div>
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<a href="http://3.bp.blogspot.com/-4TsY4cc-ijo/UXMqLOG9CfI/AAAAAAAAA4k/VWqRsEDasUY/s1600/track_ridge_omax.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="220" src="http://3.bp.blogspot.com/-4TsY4cc-ijo/UXMqLOG9CfI/AAAAAAAAA4k/VWqRsEDasUY/s640/track_ridge_omax.png" width="640" /></a></div>
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I made the water jet path come completely away from the part between each cut (shown by the green "shark teeth"). Therefore, we could check on the part if something wasn't cutting properly. </div>
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Now for the ring gear. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgb8pKtDPPdZKUVB3smPnDKsVe7OU35wdXsWEK_hMqus0QszWcohHF6Jthx6Hf_g0jAVht3yuVKqr0044sKafxlTcb4IpQrg8aamYgfBF8xxrF082mb9futwSFenUunrE4XFD3kjXU6Q2A/s1600/gear_generator.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="546" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgb8pKtDPPdZKUVB3smPnDKsVe7OU35wdXsWEK_hMqus0QszWcohHF6Jthx6Hf_g0jAVht3yuVKqr0044sKafxlTcb4IpQrg8aamYgfBF8xxrF082mb9futwSFenUunrE4XFD3kjXU6Q2A/s640/gear_generator.png" width="640" /></a></div>
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I used the Autodesk gear generator (in the assembly mode). I ended up spending a whole day playing with these numbers. After awhile, I built an intuition for what the numbers will change on the gear. </div>
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I searched for spur gears on the <a href="http://www.sdp-si.com/">SDP-SI</a> (Stock Drive Products/Sterling Instruments) website. (They have an amazing selection of mechanical parts (comparable to McMaster)). I decided to find a spur gear, and then design the ring gear around it to give myself some constraints. This gave me some values I needed in the Autodesk gear generator (like the pitch diameter and such). I found a 16 tooth gear with a 24 ul/in. pitch diameter. </div>
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SDP-SI, being the awesome online mechanical parts store they are, had a CAD file for each of their gears. I imported it into Autodesk and then "eye-balled" its fit with the ring gear. </div>
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<a href="http://4.bp.blogspot.com/-2UDCNIzg1UU/UXMktER4-VI/AAAAAAAAA4I/TxkEB5KZqwQ/s1600/ring_spur_assembly.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="360" src="http://4.bp.blogspot.com/-2UDCNIzg1UU/UXMktER4-VI/AAAAAAAAA4I/TxkEB5KZqwQ/s640/ring_spur_assembly.png" width="640" /></a></div>
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I mostly tweaked the gear ratio and center distance to get the ring gear to fit with the spur gear from SDP-SI and my CADed rim (ending up with a 10.375 gear ratio. (166 teeth on the ring gear, 16 teeth on the spur gear)). To get the teeth and holes, I took the ring bearing track and selected the inside surface for the feature in the gear generator. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5T7mcC1SFKDNw-GWPTyHFVzmCqVwaqmUET2eG0A7V6fX-33PB2IJp6F948K92YIOt7a6ui_t7D_oPAD7dRywTFrl3EquuQAigE2GP17AMf1f7SCg6NLJKVncy0Cn_l06bqxPBBIl0DNQ/s1600/ring_gear.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="572" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5T7mcC1SFKDNw-GWPTyHFVzmCqVwaqmUET2eG0A7V6fX-33PB2IJp6F948K92YIOt7a6ui_t7D_oPAD7dRywTFrl3EquuQAigE2GP17AMf1f7SCg6NLJKVncy0Cn_l06bqxPBBIl0DNQ/s640/ring_gear.png" width="640" /></a></div>
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Success!</div>
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Here's the finished rim assembly. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSFTzSmMtYe2Pu62hEEWknCImrXDyjoFxFpcpRuLNkrWCYj9OC4nfj9oZPitU1oKAIoLUjFodzrvM07uZmARWu5qqIJkilTtN2EXA_u_VIouLZiDMdFZ59SbUsHpisF4hjkQ_mTxx_eDg/s1600/rim_assembly1.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="522" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiSFTzSmMtYe2Pu62hEEWknCImrXDyjoFxFpcpRuLNkrWCYj9OC4nfj9oZPitU1oKAIoLUjFodzrvM07uZmARWu5qqIJkilTtN2EXA_u_VIouLZiDMdFZ59SbUsHpisF4hjkQ_mTxx_eDg/s640/rim_assembly1.png" width="640" /></a></div>
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<a href="http://1.bp.blogspot.com/-XkYf7jdnDr8/UXMxViXd36I/AAAAAAAAA48/m_u6fEqkWRQ/s1600/rim_assembly2.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="588" src="http://1.bp.blogspot.com/-XkYf7jdnDr8/UXMxViXd36I/AAAAAAAAA48/m_u6fEqkWRQ/s640/rim_assembly2.png" width="640" /></a></div>
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In between CADing the wheel assembly and ring gear, I CADed up a mold to be 3D printed on the IDC's 3D printer.<br />
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<a href="http://4.bp.blogspot.com/-YOzQTNWYuZA/UXOgHZxS0MI/AAAAAAAAA54/lmFiTZo7BmE/s1600/top_mold.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="http://4.bp.blogspot.com/-YOzQTNWYuZA/UXOgHZxS0MI/AAAAAAAAA54/lmFiTZo7BmE/s640/top_mold.png" width="640" /></a></div>
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The little pegs sticking out the side of the top mold will friction fit into the bottom mold piece. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7u_vj4XdCCFMjsTmwo4FcpMW9aDVFQfzVz7cFiqOKAWW74eJa1wA4B_tolYmTYydNJtcYXRKbquO7N1nWJRhN4dUkObNkbU-_BbgVGoMxCJQt_MuDswyRaYBtDCs_pbFXHsWBGoKcwlc/s1600/bottom_mold.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="484" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi7u_vj4XdCCFMjsTmwo4FcpMW9aDVFQfzVz7cFiqOKAWW74eJa1wA4B_tolYmTYydNJtcYXRKbquO7N1nWJRhN4dUkObNkbU-_BbgVGoMxCJQt_MuDswyRaYBtDCs_pbFXHsWBGoKcwlc/s640/bottom_mold.png" width="640" /></a></div>
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I put a small fillet in on the corner to make the urethane wheel rounded on the edges (but still flat in the middle). </div>
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Printed.</div>
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<a href="http://1.bp.blogspot.com/-QIy36zi-ZwU/UXMW9rELlEI/AAAAAAAAA3c/H5CowLoP6WI/s1600/2013-01-19+04.25.21+HDR.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-QIy36zi-ZwU/UXMW9rELlEI/AAAAAAAAA3c/H5CowLoP6WI/s640/2013-01-19+04.25.21+HDR.jpg" width="640" /></a></div>
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I laser cut a prototype ring gear to make sure it fit in the 3D printed mold and matched the teeth on the 16 tooth spur gear before I committed to water jetting it. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMDKMhv3VXpLCAPD29SijRF_xoxK5MROjR5y8fJz33IRpQgY1ffCPLVirDhgjfmts7W4C7KTWtTSjipDY6KaIP65zAzBu8ufzTdNvBvBM-NIBjPFUypr3IOlBhy-EaFXXA6UFbLtQIzHE/s1600/2013-01-19+04.25.56.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjMDKMhv3VXpLCAPD29SijRF_xoxK5MROjR5y8fJz33IRpQgY1ffCPLVirDhgjfmts7W4C7KTWtTSjipDY6KaIP65zAzBu8ufzTdNvBvBM-NIBjPFUypr3IOlBhy-EaFXXA6UFbLtQIzHE/s640/2013-01-19+04.25.56.jpg" width="640" /></a></div>
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I designed a two part mold to help with taking the wheel out after the urethane has been poured. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjALbQ_4Zr7YW0WJ6CckePupGDgGP0_80zsj_V2_o95jJmESHye6DFixuhmmDjiKlzfwnSpr4hIIxPiPTA49WEROhey5HYb3dnPOq2tSwxCKadHX4adAZ5S4ywIGSUCnr0OU0XpuNsAXQk/s1600/2013-01-19+04.26.20.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjALbQ_4Zr7YW0WJ6CckePupGDgGP0_80zsj_V2_o95jJmESHye6DFixuhmmDjiKlzfwnSpr4hIIxPiPTA49WEROhey5HYb3dnPOq2tSwxCKadHX4adAZ5S4ywIGSUCnr0OU0XpuNsAXQk/s640/2013-01-19+04.26.20.jpg" width="640" /></a></div>
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The little pieces that look like small top hats are inserts into the main mold frame to suspend the wheel rim in the mold. This will enable the urethane to have the same thickness on both sides of the rim. </div>
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The last batch of water jetting went much faster, because I had formatted all the *.dxf files from Autodesk into the OMAX Layout software.<br />
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<a href="http://1.bp.blogspot.com/-eaAZad3854U/UVcdTHkxNvI/AAAAAAAAAqM/UbUwU1ELPpc/s1600/2013-01-25+23.01.11.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-eaAZad3854U/UVcdTHkxNvI/AAAAAAAAAqM/UbUwU1ELPpc/s640/2013-01-25+23.01.11.jpg" width="640" /></a></div>
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This time I had enough experience to be able to operate it. I would like to give a huge thanks to Kyle for helping me with all the water jetting and for his patience during the process. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0NjGpiDdLh6ev73cFrHetctP6gFbOjvlyUcF-piZmOtyCSN58-8bO4gsIohpV9ADhlubs_kQriUwUmzbgkFxdZ7FUaE8KNspihyphenhyphenvDCEy4lxuPxYdbUYh5onACIFcjVRjjE5CLIPIb3dY/s1600/2013-01-22+20.58.45+HDR.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi0NjGpiDdLh6ev73cFrHetctP6gFbOjvlyUcF-piZmOtyCSN58-8bO4gsIohpV9ADhlubs_kQriUwUmzbgkFxdZ7FUaE8KNspihyphenhyphenvDCEy4lxuPxYdbUYh5onACIFcjVRjjE5CLIPIb3dY/s640/2013-01-22+20.58.45+HDR.jpg" width="478" /></a></div>
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I was able to combine parts in OMAX layout to get the most out of my aluminum sheet. Here's a photo of the printed bottom plate and the ring bearing track.</div>
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I set the ring gear on the highest quality (quality 5) to make sure the teeth came out perfect and would mesh with the spur gear. (I also didn't change the tool offset, because the ring gear needed to be the exact dimensions as they were in the CAD file). </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdNlBGXlS6Z_hMtwk4AZpTxcHbLwUEEGjcWR0dgjUxFQARMXSfHio3fU9ymDT5m5_BpmOFwlNZ6RnVt6pMgDQhhnv2DsuF4oD7K7a15ZZBZR2RXNX6tjxFBVXcgaGchCp_Z1LUiu3TNsA/s1600/2013-01-23+04.24.13.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdNlBGXlS6Z_hMtwk4AZpTxcHbLwUEEGjcWR0dgjUxFQARMXSfHio3fU9ymDT5m5_BpmOFwlNZ6RnVt6pMgDQhhnv2DsuF4oD7K7a15ZZBZR2RXNX6tjxFBVXcgaGchCp_Z1LUiu3TNsA/s640/2013-01-23+04.24.13.jpg" width="640" /></a></div>
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<a href="http://2.bp.blogspot.com/-pAbYJOGYw5c/UXMWv6IA2DI/AAAAAAAAA3U/7Gk0fi5lvdk/s1600/2013-01-23+04.23.46.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://2.bp.blogspot.com/-pAbYJOGYw5c/UXMWv6IA2DI/AAAAAAAAA3U/7Gk0fi5lvdk/s640/2013-01-23+04.23.46.jpg" width="640" /></a></div>
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The bearings I'm using have dimensions: 8 mm Inner Diameter, 22 mm Outer Diameter, and 7 mm Width. 7 mm is about 0.275 inches which is slightly wider than 1/4" aluminum. I used sheet metal with 1/16" thickness to shim between the bearing guides (ridges) to make a track 0.3125" wide. </div>
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<a href="http://4.bp.blogspot.com/-Y1iu9g8olHc/UXMCGVStv0I/AAAAAAAAA3M/I8Ea3TVfcis/s1600/2013-01-26+20.57.46.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://4.bp.blogspot.com/-Y1iu9g8olHc/UXMCGVStv0I/AAAAAAAAA3M/I8Ea3TVfcis/s640/2013-01-26+20.57.46.jpg" width="640" /></a></div>
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The bearings fit in the track with very little slop. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2W7oMPHVY2G6WKrQ7Tky74sucdhC_QJCcSoHVlhLiEL09KOD6f7T6-h4cgWsPpEEKBodnM5NA_3TK4cvdRDzbPT3BQqa0cjFnuwC-sGrrLtwKwtqAu89xQZDuq-5Ewh0iNIQpR5w3XKo/s1600/2013-01-26+20.16.03+HDR.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj2W7oMPHVY2G6WKrQ7Tky74sucdhC_QJCcSoHVlhLiEL09KOD6f7T6-h4cgWsPpEEKBodnM5NA_3TK4cvdRDzbPT3BQqa0cjFnuwC-sGrrLtwKwtqAu89xQZDuq-5Ewh0iNIQpR5w3XKo/s640/2013-01-26+20.16.03+HDR.jpg" width="640" /></a></div>
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Now for putting the entire wheel assembly together. I countersunk the six track ridge pieces that will be on the outside of the wheel.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiGqgXQyv3nrQOJ3lbJqIeQAwPhPXjNNYp42NTTmbkpQ_lxXdrHEYeHUA9wM97M0jr23QNavLKYUMa7m0ubNWL8Kgh-GZdGkuhIEwyXKuMHwe8HnJ-dk5gzZHdnCwjM0_e24GlJNmEMyXY/s1600/2013-01-26+20.57.54.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiGqgXQyv3nrQOJ3lbJqIeQAwPhPXjNNYp42NTTmbkpQ_lxXdrHEYeHUA9wM97M0jr23QNavLKYUMa7m0ubNWL8Kgh-GZdGkuhIEwyXKuMHwe8HnJ-dk5gzZHdnCwjM0_e24GlJNmEMyXY/s640/2013-01-26+20.57.54.jpg" width="640" /></a></div>
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I alternated the track ridges so the meeting point of two thirds was the center of one third on the second layer (staggering the pieces). I then threaded the middle three holes, and drilled through. I also carefully planned the hole diameters for the ring gear and two bearing track rings (because I didn't want to have to water jet them a second time, plus I didn't have enough material to do so). </div>
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<a href="http://2.bp.blogspot.com/-DwGTHv6REnI/UVcdVQJY0BI/AAAAAAAAArA/CDjTmhd1XGI/s1600/2013-01-26+22.01.55.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://2.bp.blogspot.com/-DwGTHv6REnI/UVcdVQJY0BI/AAAAAAAAArA/CDjTmhd1XGI/s640/2013-01-26+22.01.55.jpg" width="640" /></a></div>
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Comparison to the CAD assembly:</div>
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<a href="http://3.bp.blogspot.com/-vKcn94Hv3yA/UXMyyzBv3rI/AAAAAAAAA5U/WKL0kR3FsQ4/s1600/rim_assembly3.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="http://3.bp.blogspot.com/-vKcn94Hv3yA/UXMyyzBv3rI/AAAAAAAAA5U/WKL0kR3FsQ4/s640/rim_assembly3.png" width="640" /></a></div>
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Once I got all the proper holes drilled 0.173" and the 0.144" holes tapped, I screwed them together with 1 1/4" 8-32 screws alternating in pairs of three. The screws are screwed in from both directions resulting with a screw in every hole. I did it this way to get rid of nuts. It also makes both sides of the wheel flat to prevent big gaps between the front and back plates. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjT1nP5RNzNfHCdvKC2yfjpvmBW0Zym8PivXfUG4kjhVyCNAkzybgAyiOFfULMXOknGCPk-rJ4n4nGYieMDfGhUO4HSPWgNTi0AOcsxS9KmfA6Wify_UKPaY5IzrUPUEADGCXt22Mjdk3c/s1600/2013-01-26+22.06.11.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjT1nP5RNzNfHCdvKC2yfjpvmBW0Zym8PivXfUG4kjhVyCNAkzybgAyiOFfULMXOknGCPk-rJ4n4nGYieMDfGhUO4HSPWgNTi0AOcsxS9KmfA6Wify_UKPaY5IzrUPUEADGCXt22Mjdk3c/s640/2013-01-26+22.06.11.jpg" width="640" /></a></div>
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It fits in the 3D printed mold! It actually fit so well that I won't have to use the little plastic inserts and the big steal pipe to hold the rim up inside the mold. It has a good enough friction fit that it stays in place.<br />
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Now for the spacers to hold the bearings in their respective tracks. The spacers will also keep the wheel from rubbing on the sides of the front and back plates.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLXbWPyaa90sztK-XyoGKkkM3QKvsbhRyeOf3dg3EMTbfceuiPoJVxcBxUVdnxg34Etp9xeH5vholNVpaQ0-r13932mKyvDu4tVK8xw-V7xcYDOoRdkYx14LdGjiDhJu4JceG_8FawjYI/s1600/2013-01-28+23.17.30.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhLXbWPyaa90sztK-XyoGKkkM3QKvsbhRyeOf3dg3EMTbfceuiPoJVxcBxUVdnxg34Etp9xeH5vholNVpaQ0-r13932mKyvDu4tVK8xw-V7xcYDOoRdkYx14LdGjiDhJu4JceG_8FawjYI/s640/2013-01-28+23.17.30.jpg" width="640" /></a></div>
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I found some aluminum rod stock 3/8" in diameter at MITERS. I put it on the lathe and bored out a 0.28" hole for the steel rods to fit in. Then I used the parting tool to make 15 spacers. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbOqg8-Oclu7JeLeb5mSPKPCEs8iAamrO_q__5vfiqQVh6udHcRQXUAMSw7IlYEH2Uso9fB4sQrHQkjjBhZNng199UAtpCeQyKXdi5xtzMbSZ1zhUaVpVt0e3adMqQUsnA5SUq8DPC9IY/s1600/2013-01-28+21.34.08.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgbOqg8-Oclu7JeLeb5mSPKPCEs8iAamrO_q__5vfiqQVh6udHcRQXUAMSw7IlYEH2Uso9fB4sQrHQkjjBhZNng199UAtpCeQyKXdi5xtzMbSZ1zhUaVpVt0e3adMqQUsnA5SUq8DPC9IY/s640/2013-01-28+21.34.08.jpg" width="640" /></a></div>
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The aluminum spacers separate the bearings so they don't rub on the ridges in the wheel rim. </div>
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I put the ring gear on the side (rather than in the center of the wheel), because the motor shaft isn't long enough to support a spur gear in the center of the wheel. Now it reaches without a problem. I don't think it will matter too much that I won't have the bearing centered, because they will be leaning as I ride. It's also fairly robust as it is. </div>
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I didn't have to loosen the steel rods to put the bearings and wheel on. I managed to slid them on all at once.</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8nvmCPhWD8-PB1AZmreFgmqMPIdutoBB8iARUhfS-BeGaAmG4SX7RJaUUCr9GeNqtu0KuLRyb3hPX_U6S6UfS2LizuS1Avv4V1uUsXqahX4zlByOJ7UrPahrtnpTAzKRXaPWKutWCHMM/s1600/2013-01-28+21.33.46.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8nvmCPhWD8-PB1AZmreFgmqMPIdutoBB8iARUhfS-BeGaAmG4SX7RJaUUCr9GeNqtu0KuLRyb3hPX_U6S6UfS2LizuS1Avv4V1uUsXqahX4zlByOJ7UrPahrtnpTAzKRXaPWKutWCHMM/s640/2013-01-28+21.33.46.jpg" width="640" /></a></div>
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I designed the bearing configuration similar to my commercial orbit wheels. The three double bearings on the bottom help support my weight, and the top three keep the orbit wheel secure (they will also help with bumping into curbs or walls to stop).<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj-u5niK2qKsoO0vgeNnog8bSbFP2dC9znoAzH38zHT-VWmjV5FN57R4tPDgbrmJBpDhxlk5lEeoqYDDsGpvKxwvdxo9E41QY76tgFxFKp911884ENXnM8ckgYmnY2v9krpr-HHHXZQ1w4/s1600/2013-01-26+22.28.15.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj-u5niK2qKsoO0vgeNnog8bSbFP2dC9znoAzH38zHT-VWmjV5FN57R4tPDgbrmJBpDhxlk5lEeoqYDDsGpvKxwvdxo9E41QY76tgFxFKp911884ENXnM8ckgYmnY2v9krpr-HHHXZQ1w4/s640/2013-01-26+22.28.15.jpg" width="640" /></a></div>
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A rolling frame! The rim is finished and the bearings are in place. It looks like my CADed assembly. It is pretty much finished mechanically. Now all it needs is a motor, batteries, and electronics. Oh! and a...</div>
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<a href="http://1.bp.blogspot.com/-CqffM_SvQzg/UVcdYZFL0JI/AAAAAAAAAsA/Ako38UUsR1I/s1600/2013-01-28+22.05.21.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-CqffM_SvQzg/UVcdYZFL0JI/AAAAAAAAAsA/Ako38UUsR1I/s640/2013-01-28+22.05.21.jpg" width="640" /></a></div>
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Croc. </div>
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<a href="http://2.bp.blogspot.com/-2O2YiE_I99U/UVcdX7awmUI/AAAAAAAAAr0/oK6eLIANxnw/s1600/2013-01-28+22.04.32.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://2.bp.blogspot.com/-2O2YiE_I99U/UVcdX7awmUI/AAAAAAAAAr0/oK6eLIANxnw/s640/2013-01-28+22.04.32.jpg" width="640" /></a></div>
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<br />Jaguar Kristellerhttp://www.blogger.com/profile/08428337775851273522noreply@blogger.com3tag:blogger.com,1999:blog-2823741957408378785.post-78452349463377234802013-04-16T18:55:00.004-04:002013-05-06T04:15:51.804-04:00Changing a "Rusty 'Ole" East Campus Faucet<div style="text-align: center;">
<a href="http://2.bp.blogspot.com/-jPdvLiX4q5Y/UXO3sym6PKI/AAAAAAAAA6M/H4mhlLI0GkA/s1600/IMG_1038.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="476" src="http://2.bp.blogspot.com/-jPdvLiX4q5Y/UXO3sym6PKI/AAAAAAAAA6M/H4mhlLI0GkA/s640/IMG_1038.JPG" width="640" /></a></div>
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The sink had a terrible drain ever since my roommate was assigned the room (partly the reason we chose the other single to move into and build a <a href="http://kriste11er.blogspot.com/2013/02/loft-and-painting.html#more">double loft</a>). It also didn't look very aesthetically pleasing, especially for something that spits out "clean" water. These unpleasant traits weren't enough for me to fix the sink before, because we turned the room into a guest room (used primarily for sleeping). However, when I knew my Mom was going to use the guest room during Spring Break, I had more of an incentive to fix it.<br />
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STATUS:<br />
Faucet leaks around the side when running<br />
Sink basin is full of dirt and gunk<br />
Does not drain properly (water sits in the sink for hours)<br />
Not usable<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-zq_2THHETzV5vYI-H2vWm3hmI3J4hS9AeWImDqNdpJwvAGhVw5EcQwEpzBRBE_-qvssboVrHfVRbD8hHRhUPw5cq8NNOjhIyEY15GWYlgxyyMLeegSVh1Z1QGTkEWzWWUe7fUzL7RfY/s1600/IMG_1026.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-zq_2THHETzV5vYI-H2vWm3hmI3J4hS9AeWImDqNdpJwvAGhVw5EcQwEpzBRBE_-qvssboVrHfVRbD8hHRhUPw5cq8NNOjhIyEY15GWYlgxyyMLeegSVh1Z1QGTkEWzWWUe7fUzL7RfY/s640/IMG_1026.JPG" width="640" /></a></div>
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First, I started by turning off the flow of water by twisting the shutoff valves.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwgpuKIcGrpuUz-_XAl8u2CK-OsvwjFp2A0wukecc1KMXvXFKZCKT1jmvgLX05ed6vk07X_R7q44L1ppMBRPz8U2xhdWvRDaM8AG_hPHtufxAeIp7pGFPfHMZlpSKcSA6gwtDFsf4gBXA/s1600/IMG_1028.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjwgpuKIcGrpuUz-_XAl8u2CK-OsvwjFp2A0wukecc1KMXvXFKZCKT1jmvgLX05ed6vk07X_R7q44L1ppMBRPz8U2xhdWvRDaM8AG_hPHtufxAeIp7pGFPfHMZlpSKcSA6gwtDFsf4gBXA/s640/IMG_1028.JPG" width="640" /></a></div>
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Then I disconnected the supply lines in order to get to the threaded faucet leads.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfYHrKpv8BwRosqoBqoPfWWP788DeBHZnwTvHSre7_Pzsx3EbDea4yaWPTRxonKrPDw5eTLQmdvTbfsFguFvQcspUPKJJjlfMieygyaMSIc7IoE445-VWINiOlsMfvhCxHwsSm-aBzQbk/s1600/IMG_1034.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjfYHrKpv8BwRosqoBqoPfWWP788DeBHZnwTvHSre7_Pzsx3EbDea4yaWPTRxonKrPDw5eTLQmdvTbfsFguFvQcspUPKJJjlfMieygyaMSIc7IoE445-VWINiOlsMfvhCxHwsSm-aBzQbk/s640/IMG_1034.JPG" width="478" /></a></div>
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Unscrewing the compression couplings (the nuts on the threaded faucet leads) were a pain to get off. Partly because the sink was old, but mainly because I didn't have a basin wrench. </div>
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<a href="http://3.bp.blogspot.com/-J9mGldV2cmI/UW0tmRI-_PI/AAAAAAAAA00/FIw8GdRi3hA/s1600/IMG_1036.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="640" src="http://3.bp.blogspot.com/-J9mGldV2cmI/UW0tmRI-_PI/AAAAAAAAA00/FIw8GdRi3hA/s640/IMG_1036.JPG" width="478" /></a></div>
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Next, I unscrewed the faucet nobs.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjH6OZZAdOXTNhthHAUDc9xSZ-QCF2TDDpOl9CCztQkbUxN2oJgT5Jymnagv1vkzlBS8yzXnN9xd-DcRG2wG3em7gr7GjDNbUjbmRYs4Cy0xUqg6aBHTm2kLRADedfRPaH6yECNmcMJgok/s1600/IMG_1032.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjH6OZZAdOXTNhthHAUDc9xSZ-QCF2TDDpOl9CCztQkbUxN2oJgT5Jymnagv1vkzlBS8yzXnN9xd-DcRG2wG3em7gr7GjDNbUjbmRYs4Cy0xUqg6aBHTm2kLRADedfRPaH6yECNmcMJgok/s640/IMG_1032.JPG" width="640" /></a></div>
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The faucet came off (with a little bit of prying and brute force). </div>
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<a href="http://2.bp.blogspot.com/-jPdvLiX4q5Y/UXO3sym6PKI/AAAAAAAAA6M/H4mhlLI0GkA/s1600/IMG_1038.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://2.bp.blogspot.com/-jPdvLiX4q5Y/UXO3sym6PKI/AAAAAAAAA6M/H4mhlLI0GkA/s640/IMG_1038.JPG" width="640" /></a></div>
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30 year old plumber's putty! Yum... Let's see what Clorox has to say about that. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIR5iRPftJPQHi6UmMhZXWikCOmEhzFtw-PB6SRnRLXMgTuRkqPGWIHyN2lz7kz63bdAI6O4ToQ8YywJr7zSx_dPu6dnRwR_OEeYwCXwqRlwyBQmneFX50c1QQDlfiXvBsX8-UZMGcPOk/s1600/IMG_1040.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhIR5iRPftJPQHi6UmMhZXWikCOmEhzFtw-PB6SRnRLXMgTuRkqPGWIHyN2lz7kz63bdAI6O4ToQ8YywJr7zSx_dPu6dnRwR_OEeYwCXwqRlwyBQmneFX50c1QQDlfiXvBsX8-UZMGcPOk/s640/IMG_1040.JPG" width="640" /></a></div>
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It is truly amazing what a few minutes and Clorox wipes can accomplish. The sink looks brand new!</div>
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I took a trip on the Red Line Boston T to Andrew Station to get a faucet at Home Depot. On my way back, I saw Charles!! (He was getting supplies for <a href="http://www.etotheipiplusone.net/?cat=90">BurnoutChibi</a>). </div>
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Replacing the faucet was pretty straight forward. Though I was pretty disappointed with packaging. It said to buy plumber's putty and Teflon tape. The first thing I noticed after opening the box was a little green tag on the faucet instructing, "DO NOT USE PLUMBER'S PUTTY". It turns out I didn't need plumber's putty or Teflon tape. They used a generic box that didn't apply to this specific type of faucet (annoying). </div>
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Other than that, I hooked up the supply tubes for both the hot and cold-water supply lines. (The supply lines were stiff, but malleable, metal tubes which are often used in older buildings. This sink could potentially be 30 years old!). I then tightened the compression couplings to keep the faucet from leaking. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUe76CZAm_HR2CKqR6IYdXqonon-3u8evJC9ir38OdrbZyuFNmGJhF7k-p7HQaL7-bVIHsMyXzhfV4t574YIGDNhyf9UcQxc0TilCeHc6n4_h_J2IX_2NkX1LnHaNBwHk_mfxcDKErWiI/s1600/IMG_1046.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUe76CZAm_HR2CKqR6IYdXqonon-3u8evJC9ir38OdrbZyuFNmGJhF7k-p7HQaL7-bVIHsMyXzhfV4t574YIGDNhyf9UcQxc0TilCeHc6n4_h_J2IX_2NkX1LnHaNBwHk_mfxcDKErWiI/s640/IMG_1046.JPG" width="640" /></a><br />
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Faucet works (though water comes out fast and splatters everywhere). That's what aerator's are for!</div>
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<a href="http://2.bp.blogspot.com/-6peKZ89mOaI/UW0tpcm20WI/AAAAAAAAA1k/k6r00Y9n6BM/s1600/IMG_1044.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://2.bp.blogspot.com/-6peKZ89mOaI/UW0tpcm20WI/AAAAAAAAA1k/k6r00Y9n6BM/s640/IMG_1044.JPG" width="640" /></a></div>
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The aerator introduces a lot of air into the water stream (as the name might imply). </div>
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Next, fixing the draining problem.</div>
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<a href="http://2.bp.blogspot.com/-aTLJdxeorMU/UW3Qwl48G_I/AAAAAAAAA2s/S8aSr_OH5z0/s1600/IMG_1042.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://2.bp.blogspot.com/-aTLJdxeorMU/UW3Qwl48G_I/AAAAAAAAA2s/S8aSr_OH5z0/s640/IMG_1042.JPG" width="640" /></a></div>
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Unfortunately, the sink didn't have two threaded regions to allow for the sink trap (the U-shaped pipe underneath the sink) to be disconnected (which would have made cleaning out the trap much easier). So I had to figure out a way to clean out the trap through the "cleanout" (a little hole at the bottom of the trap). Through process of elimination, I figured out that the clog wasn't between the sink drain and the trap (it was much further in the pipe system).<br />
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Fortunately, I had access to a snake. My roommate joined Alpha Delta Phi (ADPhi) one of MIT's many fraternities. Over the first semester, I have gotten to know them fairly well hanging out with Raku and playing pool. They happened to have a snake and drill (making this job much, much easier).<br />
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<a href="http://2.bp.blogspot.com/-oV64geN_Vhs/UW0tqzaL2YI/AAAAAAAAA2I/OkGTmp0sBVs/s1600/IMG_1059.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://2.bp.blogspot.com/-oV64geN_Vhs/UW0tqzaL2YI/AAAAAAAAA2I/OkGTmp0sBVs/s640/IMG_1059.JPG" width="640" /></a></div>
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After about 10 minutes, I got this:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhP8LWEQR8m52S6iH9v3Xw9cyjhV7kcd_Ddzuq5Fpn7iMQ8cRwtK1rBYANszSzNZHBbnc4ofQa4YOaVy_W_FBZAvaWg6BK1BsteS1F19s8wyv7FbxLPW1Ed_Tl-_As5lNKWuZCEOrAkHNI/s1600/IMG_1057.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhP8LWEQR8m52S6iH9v3Xw9cyjhV7kcd_Ddzuq5Fpn7iMQ8cRwtK1rBYANszSzNZHBbnc4ofQa4YOaVy_W_FBZAvaWg6BK1BsteS1F19s8wyv7FbxLPW1Ed_Tl-_As5lNKWuZCEOrAkHNI/s640/IMG_1057.JPG" width="640" /></a></div>
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Gross...</div>
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But hey, it worked! And now the sink doesn't even think about clogging!</div>
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<a href="http://1.bp.blogspot.com/-V9QAaByQFLg/UW0tp8PD56I/AAAAAAAAA1s/EVHlAmeruJw/s1600/IMG_1055.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-V9QAaByQFLg/UW0tp8PD56I/AAAAAAAAA1s/EVHlAmeruJw/s640/IMG_1055.JPG" width="640" /></a></div>
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BEFORE:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-zq_2THHETzV5vYI-H2vWm3hmI3J4hS9AeWImDqNdpJwvAGhVw5EcQwEpzBRBE_-qvssboVrHfVRbD8hHRhUPw5cq8NNOjhIyEY15GWYlgxyyMLeegSVh1Z1QGTkEWzWWUe7fUzL7RfY/s1600/IMG_1026.JPG" imageanchor="1" style="display: inline !important; margin-left: 1em; margin-right: 1em; text-align: center;"><img border="0" height="475" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-zq_2THHETzV5vYI-H2vWm3hmI3J4hS9AeWImDqNdpJwvAGhVw5EcQwEpzBRBE_-qvssboVrHfVRbD8hHRhUPw5cq8NNOjhIyEY15GWYlgxyyMLeegSVh1Z1QGTkEWzWWUe7fUzL7RfY/s640/IMG_1026.JPG" width="640" /></a></div>
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AFTER:</div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFSbDE8oOECWWZegf-5DGmqcMFN9ADetmu2f0RPLoLxaBUH1FBBxEihoWyUk5NFm6qZPFMWnra8eypEjNI5htNUTXwvPtMEbA43lWEYoLhLF04gRmRnwXSgdqBfQ-T_0kiMxK2QmMudUc/s1600/IMG_1061.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="475" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiFSbDE8oOECWWZegf-5DGmqcMFN9ADetmu2f0RPLoLxaBUH1FBBxEihoWyUk5NFm6qZPFMWnra8eypEjNI5htNUTXwvPtMEbA43lWEYoLhLF04gRmRnwXSgdqBfQ-T_0kiMxK2QmMudUc/s640/IMG_1061.JPG" width="640" /></a></div>
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Jaguar Kristellerhttp://www.blogger.com/profile/08428337775851273522noreply@blogger.com9tag:blogger.com,1999:blog-2823741957408378785.post-21711750856348400962013-03-31T16:57:00.001-04:002013-05-06T04:15:51.742-04:00Making the Battery "Packs"<div style="text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEin5Ye3k6OqH-I3vGss57QaCz4ntEZPczt_ZUBbgwo9tPkoAbg7TnAHPtFU-xlHIXFQyla1qrgPffptxmbnEiBmCNSuleRqE_5HhyTl-g6YGwoOS0b9bV-3dKu1d135lVZmA1G-K8ymS8Q/s1600/2013-01-19+04.00.11.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="476" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEin5Ye3k6OqH-I3vGss57QaCz4ntEZPczt_ZUBbgwo9tPkoAbg7TnAHPtFU-xlHIXFQyla1qrgPffptxmbnEiBmCNSuleRqE_5HhyTl-g6YGwoOS0b9bV-3dKu1d135lVZmA1G-K8ymS8Q/s640/2013-01-19+04.00.11.jpg" width="640" /></a></div>
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Time to make a battery pack. A very oddly shaped battery pack. Before I did any soldering, I had a good discussion with <a href="http://scolton.blogspot.com/">Shane</a> and read a bit about how Charles made his battery packs for his various electric vehicles. I also sketched up a method for how I can assemble the batteries and then fold them after soldering the ribbon cables. Whiteboards help.<br />
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<a href="http://4.bp.blogspot.com/-QQ5jtv4nk7c/UVcdPpY9xsI/AAAAAAAAAo0/bkNdj_DfmoY/s1600/2013-01-21+22.24.55+HDR.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://4.bp.blogspot.com/-QQ5jtv4nk7c/UVcdPpY9xsI/AAAAAAAAAo0/bkNdj_DfmoY/s640/2013-01-21+22.24.55+HDR.jpg" width="640" /></a></div>
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Sketchings on the IDC whiteboards. Shane discussed the importance of balance leads.<br />
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<a href="http://4.bp.blogspot.com/--uXoOzorcJ0/UVcbWUW1i-I/AAAAAAAAAlY/x01NG2-BTqc/s1600/IMG_0354.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://4.bp.blogspot.com/--uXoOzorcJ0/UVcbWUW1i-I/AAAAAAAAAlY/x01NG2-BTqc/s640/IMG_0354.JPG" width="640" /></a></div>
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<span style="text-align: center;">If you want to learn how to solder battery cells into packs, a good website to read is </span><a href="http://www.etotheipiplusone.net/?p=1712" style="text-align: center;">Charles's blog</a> and/or <a href="http://viictorrodriguez.blogspot.com/2012/09/how-to-make-battery-pack.html">Victor's How to make a batter pack</a> post<span style="text-align: center;">. Here is an overview of how Charles taught me. </span></div>
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First step: it helps a lot if you sand both ends of the cell. (For A123 cells the positive terminal is what you would normally expect the negative terminal to be, the largest metal cap). The picture below shows the positive terminal.</div>
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<a href="http://1.bp.blogspot.com/-4dSpzLq6fsk/UVcdQDz7bvI/AAAAAAAAAo8/9h4zL4YAyAM/s1600/2013-01-22+00.10.59.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-4dSpzLq6fsk/UVcdQDz7bvI/AAAAAAAAAo8/9h4zL4YAyAM/s640/2013-01-22+00.10.59.jpg" width="640" /></a></div>
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Sanding the metal creates more rough edges and thus more surface area for the flux to stick to. Next apply flux to help the solder stick to the battery caps.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAg9K8HwuNS-yh5EXrvser_415pn4b0Y2sBeTveR7nywj3dcjftqzpjvrRvCx_mqVE6PI2YQYMpHJIThbYFlS67JRZ8wI8KOpQSiosJQ_ploAMDf7LUhrk76GekEgXrla2Wl25rXogi04/s1600/2013-01-22+00.11.31.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAg9K8HwuNS-yh5EXrvser_415pn4b0Y2sBeTveR7nywj3dcjftqzpjvrRvCx_mqVE6PI2YQYMpHJIThbYFlS67JRZ8wI8KOpQSiosJQ_ploAMDf7LUhrk76GekEgXrla2Wl25rXogi04/s640/2013-01-22+00.11.31.jpg" width="640" /></a></div>
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I used a liquid flux which works well, but there are other types of flux with creme/goop-like texture that also work.<br />
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<a href="http://2.bp.blogspot.com/-nCeYzQg8HL0/UVcdQrQ1kXI/AAAAAAAAApI/x7F1SVCzDcU/s1600/2013-01-22+00.11.56.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://2.bp.blogspot.com/-nCeYzQg8HL0/UVcdQrQ1kXI/AAAAAAAAApI/x7F1SVCzDcU/s640/2013-01-22+00.11.56.jpg" width="640" /></a></div>
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Once you apply the flux, you can then put a blob of solder on the battery cap. The longest you ever want to hold the soldering iron on the battery is about 3 seconds. That should be long enough to heat up the battery enough to get he solder to flow around. Any longer than 3 seconds and the battery could get damaged or start leaking.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgs2knywyYRql8NUp8XVwa_Ba63rTxO82aanJh4USP9kjByf9khSdGCwTvDtVKvkgwa7sWaJemAnQpz6ORInRoZlaVj0OpeQiacOXLvKiz_Q1-fW53JBEDdUt_A_ikLUX-BKx4WoFtTEw0/s1600/2013-01-22+00.03.24.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgs2knywyYRql8NUp8XVwa_Ba63rTxO82aanJh4USP9kjByf9khSdGCwTvDtVKvkgwa7sWaJemAnQpz6ORInRoZlaVj0OpeQiacOXLvKiz_Q1-fW53JBEDdUt_A_ikLUX-BKx4WoFtTEw0/s640/2013-01-22+00.03.24.jpg" width="640" /></a></div>
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Once the battery is primed with solder, you can connect them with ribbon cables and attach the balance leads. The pack for my electric orbit wheels isn't really a "pack" but rather a string of cells. Normally you would hot glue the cells into a configuration you wanted and solder the ribbon cables to multiple batteries (not just two, as I do in the picture above). </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYmYEn4h-3aLXtmWmqwe9bGVArhW_S3bCv_9_7V5Oy0jR1NidlaREVTxIXU9OUW25vruB7QzpFaP3c2uSU53gTS5vqqMTMuyYhz01m9qzH9WAdp4xyHil7XzEWj-Kq0h0RmnJFz7nlVMM/s1600/2013-01-21+22.24.44+HDR.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYmYEn4h-3aLXtmWmqwe9bGVArhW_S3bCv_9_7V5Oy0jR1NidlaREVTxIXU9OUW25vruB7QzpFaP3c2uSU53gTS5vqqMTMuyYhz01m9qzH9WAdp4xyHil7XzEWj-Kq0h0RmnJFz7nlVMM/s640/2013-01-21+22.24.44+HDR.jpg" width="640" /></a></div>
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I soldered on some XT60 connectors for connecting the two 5S packs in parallel between the front and back plates. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAtPhf_tlED38V4QvIRzaDZdWxOwhOprX1Ew9xnIrIoTdSwpCVc7sUuVcEPFWz6CXXD9DDWPomGUcHNVYthEblXvt0qlQUX-2xb3sb0nTDkTIToxYFZ-fIelMh6_D5e-if4CCdsfAmJ1Y/s1600/IMG_0377.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgAtPhf_tlED38V4QvIRzaDZdWxOwhOprX1Ew9xnIrIoTdSwpCVc7sUuVcEPFWz6CXXD9DDWPomGUcHNVYthEblXvt0qlQUX-2xb3sb0nTDkTIToxYFZ-fIelMh6_D5e-if4CCdsfAmJ1Y/s640/IMG_0377.JPG" width="640" /></a></div>
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To provide some sort of protection and aesthetics, I put some 1 1/4" heat shrink around the five batteries. </div>
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<a href="http://4.bp.blogspot.com/-mBK7-1HvOkU/UVcbarKwDII/AAAAAAAAAm0/JKyFIcBmLS0/s1600/IMG_0379.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://4.bp.blogspot.com/-mBK7-1HvOkU/UVcbarKwDII/AAAAAAAAAm0/JKyFIcBmLS0/s640/IMG_0379.JPG" width="640" /></a></div>
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One pack down, three more to go. I am about to run out of the heat shrink I got from MIT's Edgerton Center. I might have to get Amazon Prime and buy some from there, because HobbyKing will take too long. </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDufMZjFGZUIWmI08QDZ_7yLThBe_OeS54FiZmgKepk_hxJs7DaB512R5Lo2HTY6avRQablspugnhyIa4_WTo4WB_uv8R0-cvNy2MUe6g9oW0k-XNM6Kau3Q_t8r_417VlNXfZipD72Yc/s1600/2013-01-19+04.00.35.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhDufMZjFGZUIWmI08QDZ_7yLThBe_OeS54FiZmgKepk_hxJs7DaB512R5Lo2HTY6avRQablspugnhyIa4_WTo4WB_uv8R0-cvNy2MUe6g9oW0k-XNM6Kau3Q_t8r_417VlNXfZipD72Yc/s640/2013-01-19+04.00.35.jpg" width="640" /></a></div>
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I drilled holes through the battery clips on the MITERS mill. I had to do so very carefully otherwise the acrylic would crack when the drill bit exited the part. I also used a higher rpm for drilling through plastic. </div>
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The 12 mm clear acrylic battery clips don't crack as often as the 6 mm black acrylic clips. I marked all the balance leads to keep track of where they were connected to the pack internally. </div>
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When I tried to charge up my complete 5S2P pack, I got an error on the charger. After isolating the problem with a multimeter, I found that one of my balance leads was disconnected somewhere between the end of the last battery and the JST-XH connector. I opened it up and found the spot pretty quickly. After that it was just a quick fix with some solder.</div>
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<tr><td><a href="http://2.bp.blogspot.com/-Q82WnVP6hDE/UVcdgC7eOSI/AAAAAAAAAvI/-d32YDX7MHI/s1600/2013-02-04+04.10.33.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="478" src="http://2.bp.blogspot.com/-Q82WnVP6hDE/UVcdgC7eOSI/AAAAAAAAAvI/-d32YDX7MHI/s640/2013-02-04+04.10.33.jpg" width="640" /></a></td></tr>
<tr><td class="tr-caption" style="font-size: 13px;">Charging up the Battery Packs after Soldering<br /></td></tr>
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I've been waiting on the motors for quite some time now. I started worrying that I might not have chosen Express shipping from HobbyKing's International Warehouse. So I checked, and it turned out my Dad's credit card freaked out and didn't actually place the order because it was from Hong Kong. </div>
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It was sort of a relief knowing that they wouldn't take another month to ship (which happens if you don't choose Express), but it was also quite frustrating. I placed the order again and this time it went through. So, hopefully in a week or so the motors will show up!</div>
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Now I need to figure out how to make a ring gear with Autodesk's gear generator. Then I can cut it out on the water jet and get ready to pour a mold. </div>
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Jaguar Kristellerhttp://www.blogger.com/profile/08428337775851273522noreply@blogger.com1tag:blogger.com,1999:blog-2823741957408378785.post-51770899157702120972013-03-31T16:12:00.000-04:002013-05-06T04:15:51.790-04:00Water Jetting!!! <div style="text-align: center;">
<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgFB8khz_R6OHtSDNAhr4otRPFAFAr9dVODGcqXzSt7cztvtHBbPq4rsYOc9IAf-oo08Pvp4Ci9Mprun13JIYJcJot7BKFpuPqif8jf6GA78dULioKpXQAXMj4xXd_7RvjoMwCeAaUP8Y/s1600/IMG_0348.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="476" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgFB8khz_R6OHtSDNAhr4otRPFAFAr9dVODGcqXzSt7cztvtHBbPq4rsYOc9IAf-oo08Pvp4Ci9Mprun13JIYJcJot7BKFpuPqif8jf6GA78dULioKpXQAXMj4xXd_7RvjoMwCeAaUP8Y/s640/IMG_0348.JPG" width="640" /></a></div>
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My GRT (Graduate Resident Tutor), Kyle, on my floor, <a href="http://ec.mit.edu/halls.shtml">5W</a> (aka QED), works at CSAIL, has waterjet access, and knows OMAX.<br />
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<a href="http://www.omax.com/">OMAX</a> is the software that converts an Autodesk or a SolidWorks file into a coordinate language the waterjet can use to cut out the part. The first time I went waterjetting with Kyle, we had to format all the parts in OMAX (a couple hours of work at the computer in the waterjet room). Later that night, I got the software to be able to finish all the formatting for future water jet trips.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhv-zh8dJ-_YGsFBb6QhY9xf-5RF6lXYXrZzHhNSpvHk8SaWK4-0ITwzi6vyx3eLn85N0p6ITdiUPkfu3ACN1C4MoazKNaXBiLKnOknTq6NTHN4opK72l_rc4qnrWw1r7PzNR0SQAvql3U/s1600/omax_layout_front_plate.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="350" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhv-zh8dJ-_YGsFBb6QhY9xf-5RF6lXYXrZzHhNSpvHk8SaWK4-0ITwzi6vyx3eLn85N0p6ITdiUPkfu3ACN1C4MoazKNaXBiLKnOknTq6NTHN4opK72l_rc4qnrWw1r7PzNR0SQAvql3U/s640/omax_layout_front_plate.png" width="640" /></a></div>
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I used OMAX Layout to set the quality of the cut (how slow the water jet cuts along the edges), set the cutting path (this is extremely important, because if the water jet cuts on the wrong side or in the wrong order, parts will be messed up).<br />
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This feature helps you see what the water jet thinks the parts are. If the highlighted parts don't look right, then the lead-in and lead-outs are probably incorrect. (Check the angles of the leads and make sure they are obtuse to the direction you want the water jet to go/cut).<br />
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The OMAX water jets compensate for the cutting thickness of the water stream (with abraisive). Therefore, if the machine has a cutting diameter of 0.03" and you input that the cutting diameter is 0.03", the machine will cut the part 0.015" bigger on each side to compensate.<br />
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Because I want some parts to interlock, I didn't want the water jet to cut my parts to their exact dimension (the top of the part would be cut at its intended dimensions, but the bottom would be slightly over-sized due to the diffraction of the water jet stream, the taper).<br />
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So, I "tricked" the machine by inputting a cutting radius 0.014" (cutting diameter 0.028"), a smaller cutting diameter (its actual cutting diameter <i>is</i> 0.03"). This would cause the water jet to center its nozzle closer to the dimensions of my part, which would then cause the water jet to cut the parts 0.014" smaller around all the edges. Success! Sort of. I didn't input the right thickness to trick the water jet enough. So I consulted <a href="http://yameb.blogspot.com/">DGonz</a>, who has experience cutting t-nutted parts on the CSAIL water jet, and he said 0.0115" works and requires no sanding afterwards.<br />
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Kyle taught me the <a href="http://fab.cba.mit.edu/content/tools/machines/omax_waterjet/">process</a> of turning on and operating the CSAIL water jet. There are a bunch of valves and buttons to push in certain order otherwise things aren't happy. (This post is more about documenting that I water jetted parts rather than a step-by-step instruction of how to use the CSAIL water jet). </div>
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgFB8khz_R6OHtSDNAhr4otRPFAFAr9dVODGcqXzSt7cztvtHBbPq4rsYOc9IAf-oo08Pvp4Ci9Mprun13JIYJcJot7BKFpuPqif8jf6GA78dULioKpXQAXMj4xXd_7RvjoMwCeAaUP8Y/s1600/IMG_0348.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjgFB8khz_R6OHtSDNAhr4otRPFAFAr9dVODGcqXzSt7cztvtHBbPq4rsYOc9IAf-oo08Pvp4Ci9Mprun13JIYJcJot7BKFpuPqif8jf6GA78dULioKpXQAXMj4xXd_7RvjoMwCeAaUP8Y/s640/IMG_0348.JPG" width="640" /></a></div>
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Look at it go! </div>
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So cool!</div>
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Voila!</div>
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<a href="http://2.bp.blogspot.com/-roeHJ1XFVMg/UVcbU4ELQ-I/AAAAAAAAAlM/aEkO8VdqKS8/s1600/IMG_0342.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://2.bp.blogspot.com/-roeHJ1XFVMg/UVcbU4ELQ-I/AAAAAAAAAlM/aEkO8VdqKS8/s640/IMG_0342.JPG" width="640" /></a></div>
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My first water jetting experience was a success thanks to Kyle! We were able to cut out the inside plates and back plate before the water jet started having problems cutting all the way through a 1/4 aluminum plate (evidence: water was shooting up and spraying everywhere rather than escaping beneath the part).<br />
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The water jet is out of commission for now until they fix the nozzle. (It had worn down after a lot of use. It wasn't explicitly broken by us). It will take a couple days to ship, test, and replace it. Until then, I have enough parts to start machining and assembling them into an orbit wheel shape.<br />
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I first drilled and tapped the inside plates using the mill and a 8-32 tapping bit.<br />
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I tapped down 3/4" because the first 1/4" of tap doesn't contribute to the threading. Therefore, I would end up with a good 1/2" of threads for my 3/4" flat head 8-32 black-alloy socket screws I ordered from McMaster. (The screws will go through a 1/4" aluminum plate before threading into the tapped holes, thus only 1/2" needs to be tapped). </div>
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<a href="http://1.bp.blogspot.com/-tqQX0U0iZbo/UVcdRQ0h38I/AAAAAAAAApg/lc6V9mL-Iu8/s1600/2013-01-22+23.39.11.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://1.bp.blogspot.com/-tqQX0U0iZbo/UVcdRQ0h38I/AAAAAAAAApg/lc6V9mL-Iu8/s640/2013-01-22+23.39.11.jpg" width="640" /></a></div>
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I countersunk the holes with the mill, because they look so much nicer when done on a mill. A cool trick Ben showed me for knowing how deep to countersink: If you can fit the head of the screw in the countersunk hole then it will sit nice and flush when screwed in. </div>
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I filed off the edges of the countersunk holes with a small file, and then screwed the inside plate assembly to the back plate. </div>
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Because the water jet has a small taper, I made the wider edge face towards the hole to prevent having big gaps on the outside. </div>
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I finished machining the parts I water jetted. Now I can start working on the posts that span between the front and back plate. These will also hold the VXB bearings which will support the wheel and ring gear. </div>
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This pic shows all the screws that go through the back plate. I used 1 1/4" 8-32 black-alloy flat head socket screws from McMaster for going through the battery clips. </div>
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I used some of Ben's scrap steel rod stock from his <a href="http://build-its-inprogress.blogspot.com/2012/12/building-differential.html">differential</a> which he built for his "death trike". I made six 1.5" rods and tapped them for 8-32 flat head socket screws. It's amazing how much a small drop of cutting fluid helps with tapping!</div>
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I made the steel rods stick out past the inside plates by a couple thousandths of an inch to make sure the front plate is mainly supported by the steel rods. The inside plates are just to cover up the ring gear (and potential aluminum flakes) inside. </div>
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<a href="http://3.bp.blogspot.com/-00WWo0LOUp8/UVh7fdrHcJI/AAAAAAAAAzI/oJcvq5nLSFQ/s1600/IMG_0373.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://3.bp.blogspot.com/-00WWo0LOUp8/UVh7fdrHcJI/AAAAAAAAAzI/oJcvq5nLSFQ/s640/IMG_0373.JPG" width="640" /></a></div>
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I got a deal on the <a href="http://www.vxb.com/page/bearings/PROD/Kit8031">bearings</a> from <a href="http://www.vxb.com/">VXB</a> (30 bearings for only twenty dollars, plus a cheaper set of digital calipers). They recently updated their site so it's much easier to navigate. The 8 mm inner diameter fit well over the steel rods.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4Kba6MYYpLfnvf1eMDxe-GG98C-eoRY5mn_XYJeCh38jrNFGoM190m5PbiGW74beoBcfnuzY_rRmmpeY0MC7R_pnjQO-jBEEoEuXQidxuKFJlk-7WLlq0zth3Xuc1cbIb-CKSjJ03Xd8/s1600/IMG_0371.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg4Kba6MYYpLfnvf1eMDxe-GG98C-eoRY5mn_XYJeCh38jrNFGoM190m5PbiGW74beoBcfnuzY_rRmmpeY0MC7R_pnjQO-jBEEoEuXQidxuKFJlk-7WLlq0zth3Xuc1cbIb-CKSjJ03Xd8/s640/IMG_0371.JPG" width="640" /></a></div>
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I had to sand down the bottom support plates in order to get them to interlock with the back plate. I guessed wrong on the water jet tool offset (cutting thickness/width). For next time, I know it is 0.011 thanks to DGonz.<br />
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Next is the battery pack. I've got some ideas on how to connect them into a 5S2P pack, but I need to talk with some experts (Charles and Shane). </div>
Jaguar Kristellerhttp://www.blogger.com/profile/08428337775851273522noreply@blogger.com0tag:blogger.com,1999:blog-2823741957408378785.post-75195069208495078412013-03-30T12:33:00.001-04:002013-07-13T18:00:57.223-04:00CADing: Preparing for Water Jet<div class="separator" style="clear: both; text-align: center;">
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Since I didn't really elaborate on the CADing aspect of the laser cut acrylic orbit wheel prototype in the previous post, here's the story behind it:</div>
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I've been CADing with Autodesk Inventor since 2008 when we built little puzzle cubes in my Introduction to Engineering and Robotics at Lathrop High School. Many people at MIT use SolidWorks, but I can't give up that nice little cube in the top right corner of Autodesk. Eager to start my new project, I decided to go with Autodesk. Maybe I will do my next project in SolidWorks.<br />
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I'm spending a lot of time refining my CAD files before printing them on the water jet. I can't use the free scrap stock in MITERS' pile of metal, because there aren't any water jetable 1/4 thick 8 inch squares. By "water jetable" I mean that there must be enough metal on the edges of the part in order to clamp it down to the machine. Therefore, I want to make the Autodesk files as detailed as possible to avoid wasting the nice 8" wide aluminum stock I got from <a href="http://www.mcmaster.com/">McMaster</a>.<br />
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As of now, the orbit wheel consists of 9 major aluminum (to be) water jetted parts.<br />
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The front and back plates took the most planning, because I had to plan out how my croc would fit inside the wheel and bearings. After putting together the t-nutted laser cut orbit wheel, I decided to make my "final" prototype without t-nuts. This change led to getting rid of the tongue and grooves on the front and back plates.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEje-TgFUcW8usQVjRe_iGy9ZfGT8wdllopfiBYwuQ69MF800nEgYt0GAnPM-D219Kz2jB_22MRgJAEphMzof65Hxr5oWXrY_uVFRTd2Gf93rJNU7Z0aLxEHYAC9fyoyzw9ZMWgehZGzK2M/s1600/back_plate.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="520" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEje-TgFUcW8usQVjRe_iGy9ZfGT8wdllopfiBYwuQ69MF800nEgYt0GAnPM-D219Kz2jB_22MRgJAEphMzof65Hxr5oWXrY_uVFRTd2Gf93rJNU7Z0aLxEHYAC9fyoyzw9ZMWgehZGzK2M/s640/back_plate.png" width="640" /></a></div>
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I had to estimate the motor screw holes for the front plate, because the motor is still on its way from HobbyKing's International Warehouse. I extended the holes in order to provide some way to adjust how the gear teeth mesh. Other than that, the front and back plates are nearly identical.<br />
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<a href="http://1.bp.blogspot.com/-3qG20gJtSi0/UVZFT5ugYgI/AAAAAAAAAj8/iEHdw36Zvdc/s1600/front_plate.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="568" src="http://1.bp.blogspot.com/-3qG20gJtSi0/UVZFT5ugYgI/AAAAAAAAAj8/iEHdw36Zvdc/s640/front_plate.png" width="640" /></a></div>
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The inside parts were relatively easy (rectangles):<br />
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<a href="http://4.bp.blogspot.com/-EclYheVNZTc/UVZQeDt9vuI/AAAAAAAAAkg/iT9NBOnnOgU/s1600/top_plate.png" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" height="400" src="http://4.bp.blogspot.com/-EclYheVNZTc/UVZQeDt9vuI/AAAAAAAAAkg/iT9NBOnnOgU/s400/top_plate.png" width="295" /></a><a href="http://3.bp.blogspot.com/-YE0Yo6iat84/UVZQePEvV5I/AAAAAAAAAkc/c-Cp2BwgPZo/s1600/side_plate.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="400" src="http://3.bp.blogspot.com/-YE0Yo6iat84/UVZQePEvV5I/AAAAAAAAAkc/c-Cp2BwgPZo/s400/side_plate.png" width="295" /></a></div>
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The plate on the left is the inside side plate (there will be two of these). And the one on the right is the inside top plate.<br />
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Here's the bottom plate:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSFSD8255ZSYiD-Ui2-tbs2PhlDOjyjPNDZ5Nnl8pzWxhZrP7eHhQMYj5SnJSaAEY8aPTxvnk7pT-mzCYYKyGGeSx_Qu92OqucS8PJhYvO3OixqFKZPWIw8TgOboDdfgyEteHnq1PCYf8/s1600/bottom_plate.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="640" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSFSD8255ZSYiD-Ui2-tbs2PhlDOjyjPNDZ5Nnl8pzWxhZrP7eHhQMYj5SnJSaAEY8aPTxvnk7pT-mzCYYKyGGeSx_Qu92OqucS8PJhYvO3OixqFKZPWIw8TgOboDdfgyEteHnq1PCYf8/s640/bottom_plate.png" width="608" /></a></div>
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I made the bottom plate and support plates able to interlock, because I didn't want to put four screws through the support plates. (They also interlock with the back and front plates). </div>
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<a href="http://1.bp.blogspot.com/-m4rwKU5OI0c/UVZSfdHoxqI/AAAAAAAAAks/c--BsHRnM30/s1600/bottom_support_plates.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="572" src="http://1.bp.blogspot.com/-m4rwKU5OI0c/UVZSfdHoxqI/AAAAAAAAAks/c--BsHRnM30/s640/bottom_support_plates.png" width="640" /></a></div>
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I decided to make the support plates, because the acrylic orbit wheel's bottom plate broke during my travels to and from Alaska for Winter Break. Even though aluminum is much sturdier than acrylic, I wasn't sure how the aluminum would hold up if it ever scraped on the ground.<br />
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Besides the fact that the bottom plate is broken, the laser cut prototype still helps with visualizing where I can fit the batteries.<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgt1W7_uwDDGHeReMHPTKpYJJBtgKjWN02Ooeo10bdodp14A1Xu2wrPnegVwt737p_Qjdql7xcTAdzjIq_txSmQjXZ7Yi-OwSXir9mj2vfjw8m3PmTH0s3Qpw8AaT2VYhMV4TIy9p3H5EA/s1600/IMG_0108.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em; text-align: center;"><img border="0" height="478" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgt1W7_uwDDGHeReMHPTKpYJJBtgKjWN02Ooeo10bdodp14A1Xu2wrPnegVwt737p_Qjdql7xcTAdzjIq_txSmQjXZ7Yi-OwSXir9mj2vfjw8m3PmTH0s3Qpw8AaT2VYhMV4TIy9p3H5EA/s640/IMG_0108.JPG" width="640" /></a><br />
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I need to fit at least 5 A123 cells in series to get approximately 16.5V for the motors I ordered. I really want to be able to fit ten cells and make two 5S packs to hook up in parallel to get more distance out of this electric "vehicle". This would give me about 4600 mAh. With this arrangement, I can fit 10 cells. Due to the motor on one side, I might need to put 6 cells on the opposite side and 4 cells on the side with the motor. However, this will make the wiring really ugly. <br />
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Here's a picture of one of my first CADed battery holders:<br />
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<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjj28fK-5Vrb5NwOKWKo6F9Hu8BBTDi0nH-Y7Il-xlVcHkU8vLLM8CN0WA5-COln-oUimBXp-z6PeB0KcHXUXTPXuaiXuu76lT1tLxYxLa3ffVIBRB4S8UUIURPMSXL1nTY9z45cV_leQc/s1600/multiple_batt_holder.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="376" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjj28fK-5Vrb5NwOKWKo6F9Hu8BBTDi0nH-Y7Il-xlVcHkU8vLLM8CN0WA5-COln-oUimBXp-z6PeB0KcHXUXTPXuaiXuu76lT1tLxYxLa3ffVIBRB4S8UUIURPMSXL1nTY9z45cV_leQc/s640/multiple_batt_holder.png" width="640" /></a></div>
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I decided to put 5 cells on each side to solve the wiring problem. This also opens up some more room in case the motor controller doesn't fit inside underneath the ring gear.<br />
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With this battery layout in mind, I CADed some A123 cell clips and since I didn't have to wait on a water jet I printed a few out on the laser cutter.<br />
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<a href="http://3.bp.blogspot.com/-gaVW29MHfDw/UVY_4f_8suI/AAAAAAAAAjs/i2M2fSVRMXU/s1600/single_batt_holder.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="563" src="http://3.bp.blogspot.com/-gaVW29MHfDw/UVY_4f_8suI/AAAAAAAAAjs/i2M2fSVRMXU/s640/single_batt_holder.png" width="640" /></a></div>
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<a href="http://4.bp.blogspot.com/-v94I4YGqbi4/UVY_4V9mCFI/AAAAAAAAAjw/X0E6S7chA-I/s1600/double_batt_holder.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="464" src="http://4.bp.blogspot.com/-v94I4YGqbi4/UVY_4V9mCFI/AAAAAAAAAjw/X0E6S7chA-I/s640/double_batt_holder.png" width="640" /></a></div>
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I made one side flat so I could slip them over the batteries. I had to play around with the spacing, because I also plan to put heat shrink around the batteries to protect them in a pack. Notice, one side is slightly shorter than the other to allow the clip to grip on the batteries better.<br />
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I asked around for a safe material that I could laser cut, but that would also be strong enough to hold batteries. At first I thought I might be able to use PVC sheets, but that is especially bad to cut with a laser. Ed Moriarty (runs the Saturday Thing at MIT's <a href="http://www.facebook.com/MITEdgertonCenter">Edgerton Center</a>) said that laser cutters could cut ABS, but it makes the lense very unhappy. I could use the band saw to cut them out, but that takes more time and it's not as pretty. MITERS had some acrylic scraps which seemed to be a good starting point.<br />
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<a href="http://4.bp.blogspot.com/-j_88TlfeOrk/UVY8Ct_9xVI/AAAAAAAAAjc/luneXseMw5k/s1600/2013-01-20+04.14.25.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://4.bp.blogspot.com/-j_88TlfeOrk/UVY8Ct_9xVI/AAAAAAAAAjc/luneXseMw5k/s640/2013-01-20+04.14.25.jpg" width="640" /></a></div>
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The "0.25" black acrylic (which is really 6 mm) was too small and too weak to drill and tap for holding batteries. So, I found some 12 mm clear acryclic which worked a bit better. </div>
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<a href="http://4.bp.blogspot.com/-p2d_jOhFK5I/UVY8C-m99NI/AAAAAAAAAjg/bchvrXgCoug/s1600/2013-01-20+04.30.25.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="478" src="http://4.bp.blogspot.com/-p2d_jOhFK5I/UVY8C-m99NI/AAAAAAAAAjg/bchvrXgCoug/s640/2013-01-20+04.30.25.jpg" width="640" /></a></div>
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I can't do much now until I get some parts water jetted. Until then, here are a few pretty pictures of the complete assembly in Autodesk:<br />
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<a href="http://3.bp.blogspot.com/-hi39tCBf6sc/UVVElKUTNbI/AAAAAAAAAig/xue9tXpOGXc/s1600/topside_ortho_noraytrace.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em; text-align: center;"><img border="0" height="552" src="http://3.bp.blogspot.com/-hi39tCBf6sc/UVVElKUTNbI/AAAAAAAAAig/xue9tXpOGXc/s640/topside_ortho_noraytrace.png" width="640" /></a></div>
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This is an orthographic view of the complete assembly. The black cylinders are A123 cells, and the oval with four circles in the front is where the motor goes. My ankle will be on the otherside. I usually build in this view and with this level of detail. However, there are a bunch of visual aspects to play around with. </div>
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I experimented with ray tracing, perspective, and shadows below. </div>
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<a href="http://1.bp.blogspot.com/-_g1Nzs0Q6Mo/UVVElLiSzRI/AAAAAAAAAic/4LMvK6DWoLw/s1600/underside_nobatts.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="566" src="http://1.bp.blogspot.com/-_g1Nzs0Q6Mo/UVVElLiSzRI/AAAAAAAAAic/4LMvK6DWoLw/s640/underside_nobatts.png" width="640" /></a></div>
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Here's a nice shiny ray traced image with perspective. My computer made loud fan sounds, but they didn't last too long. This view shows the orbit wheel without batteries and shows the interlocking supports for the bottom plate.<br />
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I like this one the best:<br />
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<a href="http://4.bp.blogspot.com/-YdKIl6tUocg/UVVElMF-amI/AAAAAAAAAik/wogIuE5wp0c/s1600/topside_batt.png" imageanchor="1" style="margin-left: 1em; margin-right: 1em; text-align: center;"><img border="0" height="542" src="http://4.bp.blogspot.com/-YdKIl6tUocg/UVVElMF-amI/AAAAAAAAAik/wogIuE5wp0c/s640/topside_batt.png" width="640" /></a><br />
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Ready to water jet! Now I just need to find someone to get me into either CSAIL's (Computer Science and Artificial Intelligence Laboratory) or Media Lab's water jet.<br />
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Know anyone?Jaguar Kristellerhttp://www.blogger.com/profile/08428337775851273522noreply@blogger.com0tag:blogger.com,1999:blog-2823741957408378785.post-2244283269596055922013-03-30T02:30:00.001-04:002013-05-06T04:15:51.743-04:00Picking out Motors and BatteriesAs this is my very first electric vehicle and first big project at MIT, I didn't know what type of motor would work best. I talked with Ben, <a href="http://build-its.blogspot.com/">an experienced tinkerer</a>, and he recommended a motor with low kv and pointed me towards <a href="http://www.hobbyking.com/hobbyking/store/index.asp">HobbyKing</a>. (The lower the Kv the more torque the motor can produce).<br />
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Chibikart's motors are <a href="http://www.instructables.com/id/Chibikart-Rapid-Prototyping-a-Subminiature-Electr/step13/Step-13-Prepare-the-Drive-Motors/">Turnigy 5065-256Kv Brushless Outrunner Motor</a> and have a can diameter of 49 mm. After looking on HobbyKing's website for a while I found a similar motor to <a href="http://www.etotheipiplusone.net/?cat=90">Chibikart's</a>. I ended up ordering three <a href="http://www.hobbyking.com/hobbyking/store/__18170__Turnigy_Aerodrive_SK3_4250_350kv_Brushless_Outrunner_Motor.html">Turnigy 4250-350Kv Brushless Outrunner Motor</a>s with a can diameter of 42 mm. I left my browser on the HobbyKing page for awhile and they gave me a discount! <br />
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<a href="http://3.bp.blogspot.com/-fRDnWd6wtoQ/UVXeqvTfEkI/AAAAAAAAAi8/Na4VVNVwj30/s1600/turnigy_4250_350kv_brushless_outrunner_motor.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="468" src="http://3.bp.blogspot.com/-fRDnWd6wtoQ/UVXeqvTfEkI/AAAAAAAAAi8/Na4VVNVwj30/s640/turnigy_4250_350kv_brushless_outrunner_motor.jpg" width="640" /></a></div>
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I'm thinking after I gear it for torque with the ring gear, the motor will be able to move a decent sized human at a decent rate (faster than orbit wheels without a motor that is).<br />
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Now that I got my motor picked out, I started thinking about batteries.<br />
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I decided to use the big A123 28650 Systems Lithium Nanophosphate cells. They seem to be a popular and common choice at MITERS.<br />
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<img src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhtQgEKT_WBN9n3XqIpeVg3cjR9pUDyZ0HvDLPqbeGIQSSV81jRTp8OCSGp7a65yEwTuDWeReiscLCB1r3VaX1ODaWiAXNDKCxpQbxOpOWc0J8IeYzk5UvNc4Cw2azB7ZjFrVDlPyoIwKI/s640/20121214_153113.jpg" /><br />
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I spent a lot of time researching what type of wheel I could use. I couldn't find many hubless wheels that were big enough to put my foot through (and even if I did they didn't have a ring gear inside). So I decided to build my own ring gear rim and pour the urethane rubber around it in a 3D printed cast.<br />
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And since I was planning on making my own wheel, I wanted to make "no crush wheels" so I could have some sort of shock absorption in the wheel itself.<br />
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<a href="http://3.bp.blogspot.com/-vpFitc4bPeo/UVeX48yHESI/AAAAAAAAAx8/SAz8CfPdkw4/s1600/no_crush_wheels1.jpg" imageanchor="1" style="clear: left; float: left; margin-bottom: 1em; margin-right: 1em;"><img border="0" src="http://3.bp.blogspot.com/-vpFitc4bPeo/UVeX48yHESI/AAAAAAAAAx8/SAz8CfPdkw4/s1600/no_crush_wheels1.jpg" style="cursor: move;" /></a><a href="http://4.bp.blogspot.com/-BOXSDG-sxZM/UVeYC9znYRI/AAAAAAAAAyE/An_sZDbdHdo/s1600/no_crush_wheels2.jpg" imageanchor="1" style="clear: right; float: right; margin-bottom: 1em; margin-left: 1em;"><img border="0" src="http://4.bp.blogspot.com/-BOXSDG-sxZM/UVeYC9znYRI/AAAAAAAAAyE/An_sZDbdHdo/s1600/no_crush_wheels2.jpg" /></a><br />
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In order to make these, I bought some molding urethane from Smooth-On. They sell 80A shore (a measure of how hard the material is) Urethane Rubber, which is very similar to the hardness of skateboard wheels, in little trial sizes and gallon sizes. I decided to purchase a trial size to test out if it would work for my purpose.<br />
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<a href="http://2.bp.blogspot.com/-HAH0Ilv92oI/UVeY3aSHLEI/AAAAAAAAAyM/leqKXnLTwHE/s1600/smooth_on_urethane.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="480" src="http://2.bp.blogspot.com/-HAH0Ilv92oI/UVeY3aSHLEI/AAAAAAAAAyM/leqKXnLTwHE/s640/smooth_on_urethane.JPG" width="640" /></a></div>
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I'm planning on building one orbit wheel at a time (rather than simultaneously) to test how well the no crush wheel idea works. I could have some problems with getting the stiffness of the shock absorption just perfect. Otherwise, if it is too flimsy it will be like riding a flat tire, and if it's to stiff it won't be any different than a regular wheel. This way, I can incorporate any changes and improvements into the second wheel.<br />
<br />Jaguar Kristellerhttp://www.blogger.com/profile/08428337775851273522noreply@blogger.com0