Re: what sort of lathe sufficient for adapter plate and making keyway

Thanks for the kudos. Several thoughts on cutting steel:

Try to buy the steel in as close to finish size as you can -- my spacer was ring rolled from 1/4 x 3 inch flat bar. I will still need to machine it to the final thickness. Also, the steel store can do coarse cuts for you.

I put a steel cutting "blade" in a chop saw, works great for smaller cuts.

For the smaller precise motor centering hole, I cut that by turning the piece on a rotary table and cutting with a mill.

I have also used a plasma cutter, but it makes the metal hard to machine. It is good for cuts that do not need to be precise or later machined.

I sometimes use a hand held die grinder for small cuts.

I would like to get a band saw, but have been getting by OK with my alternate, at-hand methods.

On the strength of your posts: Don't forget, it is not just the gradual torque of the motor. The motor can click on with enough suddenness the posts get a hammer-like blow. You should inspect them regularly.

Last random thought: I have thought an old truck brake drum could make a good spacer. I didn't go that route for these reasons:

        * My custom size clears both the motor bolts and the tranny bolts -- a bigger spacer would need access holes cut, and a smaller spacer wouldn't be as strong
        * The custom size made things as light and strong as possible
        * The spacer does double duty as a racing scatter shield in case the flywheel explodes (needs to be 1/4 inch by Salt Flats racing rules)

Thanks again for your video, it is great to see you jumping in and getting things done!


----- Original Message ----
From: paul holmes <barbiesbla@...>
To: ev@...
Sent: Saturday, July 5, 2008 9:41:13 AM
Subject: Re: [EVDL] what sort of lathe sufficient for adapter plate and making keyway


I really wanted to do your idea of a ring of 0.25" steel like you did, but I didn't think to make a ring roller.  That was awesome!  Also, I don't have a good way to make cuts in steel at this time, other than with a hand held grinder.  I searched for a REALLY BIG steel pipe to cut short, but to no avail.  

As far as torque goes, this car is going to be basically an NEV that goes 0-35 with very slow acceleration.  The torque I hope will be small enough so as not to mess up the spacers.  If not, I may put in steel spacers.  Also, I'm going to seal the motor compartment from the elements below.

Next time, I would like to do a spacer ring.  Thanks for posting your
progress!  I'm really impressed!  How do you cut the steel so precisely?


     
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