I've been working in it some more; it have to get it crated and shipped in a couple of weeks.
It needs a subshaft; the total reduction is 5.3/1
The gear was on a transmission shaft that's VERY hard, so I cut it off and welded it to this 30mm mild steel rod.
I had the hub sent from Holland; making a flange to fit the large gear I took out of a friend's car 15 years ago.
To help keep things cool, I smeared heat sink compound over the field coil armatures. Hopefully a lot of heat will go to the water jacket instead of heating the air that the armature needs.
Then copper grease on the screw threads and a little dab of permatex on the mating surface to keep the water on the right side.
Pressure testing the water jacket.
Water cooling plate for the electronic speed control
Pulleys + gears
Pressing on the pulley flange;
Pressing on the fan adapter shaft;
I made 2 extra connection bolts to make the series motor reversible. The connection plate already had the holes in it for them.
with fan mounted; I pulled the cage from a 1/2HP ventilator I had on a shelf for the last 15 years.
This is for the 'throttle', I'm adapting an industrial safety switch box to rotate a potmeter.
Could be overkill, but I had it lying around and it has a nice SS shaft with rotation limit ears already on it.
I made a little brass knob for the potmeter; ratio is calculated to get me the correct resistance range.
It looks fancy but this was quick work.
This is a pain of a job; cutting a slot for the belt tensioner. I want a milling machine!
Lining up the subshaft tube with a laser. finicky work but it has to be done.
Getting it into position with the lights on.
All done; the bolts will be replaced with countersunk allen screws when they get here.
Now to get started on the electrics.
CHEAP! this power meter cost 15 euros, and the same again for a 500A shunt. The thermometers were 10 euros for 5 of them. I made a 1.5V regulated power supply from parts I had leftover, so they won't need the little button cells.
One thermometer for the cooling air, the other for the water jacket.
In the picture I have it connected to my car battery for testing, but it will be a 48V system
I made this holder for the air temp sensor from scrap polycarbonate.
The one for the water jacket I made from brass and soldered in. this went easy.
I bought 2 of these 24V pumps from ebay, 8 euros each. I didn't realize they were so small; but I tested one and it performs as advertised. For how long? who knows.