Deleted
Joined: January 1970
Posts: 0
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Post by Deleted on Mar 27, 2016 8:05:00 GMT -5
We used a 240volt router £29.00 from B & Q. Good for work shop testing Good ideal, its worked well for you, me and others over here, before things moved on |
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Post by racket on Mar 28, 2016 19:15:11 GMT -5
Yep , router are pretty good , but I need a bit more horsepower , those 2400 W units are kinda expensive .
I've started designing up a gearbox for the Denso starter using its own gears but "reversed" to get the speedup required , by using the idler intermediate gear fitted to the electric motor and a motor shaft minus armature bits , I get a 2.888 :1 ratio , with only a tad over 10,000 rpm on the motor I'll have my 30,000 to the comp nut ...........hopefully :-)
Cheers
John
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daniel
Member
Joined: September 2014
Posts: 10 
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Post by daniel on Mar 30, 2016 2:20:46 GMT -5
Hi But be aware that you'll load the motor 3 times as much as w/o the gear. If it already got hot before then run for cover  Dan |
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Post by racket on Mar 30, 2016 2:58:56 GMT -5
Hi Dan
Yep , I'll be very aware of overheating the starter.
Currently it takes ~2 seconds to accelerate the rotor to 10,000 rpm with direct drive , I doubt it'll take much more than an extra second or so with the stepup gearing due to the characteristics of the DC motor , the whole spoolup should be over in 10 seconds max.
The reason it got hot before was because of the several start attempts in succession without adequate cooling times inbetween .
Cheers
John
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daniel
Member
Joined: September 2014
Posts: 10
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Post by daniel on Mar 30, 2016 5:11:40 GMT -5
Fingers crossed for a successful start then!  |
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Post by racket on Apr 4, 2016 23:45:19 GMT -5
Hi Guys The starter motor gearbox is coming together.     Just a new coupling and mount to make . Cheers John |
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Post by enginewhisperer on Apr 5, 2016 1:34:55 GMT -5
that looks very nice |
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Post by smithy1 on Apr 5, 2016 14:46:42 GMT -5
Wow John, you have been busy....nice looking bit of "ratio increase" you have there...I make it out to be ~2.88:1 -ish step-up..yes..? Hopefully the starter motor has enough grunt to pull it.
Also... I can confirm I'll be up your way on Fri 6th & Sat 7th May for a car show at the local Go-Kart track on the Saturday.
Cheers,
Smithy.
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Post by racket on Apr 5, 2016 16:39:13 GMT -5
Hi Smithy
Yep , 2.88:1 , if you checkout the graph on the previous page at the ~300 amp position , that starter has only 1,000 rpm at the pinion but max Kw , if the rpm rise the power drops off badly along with the amps , auto starters need lotsa resistance to rotation to get the amps up , I'm hoping the "high" gearing will force it to suck the amps.
LOL, I know the kart track well , I've got history there ;-)
Its marked on the calendar , I'll be there for sure , I wanna hear her scream , the punters at the track were impressed by the 2 shaft kart when I fired her up , the 6041 on full A/B will be something they won't forget .
Cheers
John
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Post by racket on Apr 8, 2016 17:05:27 GMT -5
Hi Guys New "spider" mount made , it needed to fit the existing holes so some extra work involved making the jig , but the result seems to be OK ............LOL, it bolted up OK  One positive with the new setup is less restriction of the bellmouth inlet , the starter will be able to be removed after spoolup  The starter slips into the mount and with the couple of projecting gearbox case screws to counter any torque reaction during spoolup , its looking like it just might work  Just the coupling to make up and I'll be ready for another attempt at getting her fired up next week , I'll do some testing without fuel to see if theres been any improvement with output rpm obtained from slowing down the electric motor . Cheers John |
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Post by finiteparts on Apr 9, 2016 13:38:41 GMT -5
John,
The engine is looking great! I must commend you on your excellent workmanship! Can't wait to see it come to life.
Best of luck!
Chris
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Post by racket on Apr 9, 2016 17:19:01 GMT -5
Thanks Chris
Hopefully it will fire up this week , if not then I might need to look inside to see if theres another reason, as this modified starter should do the job.
Cheers
John
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Post by Johansson on Apr 10, 2016 0:26:43 GMT -5
Best of luck John!
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Post by racket on Apr 10, 2016 2:23:20 GMT -5
Thanks Anders :-)
Initial alignment test appears to suggest the extra time taken making the jig has paid off as the coupling slid smoothly over the comp nut .
Just waiting for the matt black paint to dry and I'll fit the reflective tape for the tach , then final assembly and some testing, can't wait to see if the weeks work building the gearbox has been worth it .
Cheers
John
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Post by smithy1 on Apr 10, 2016 14:26:42 GMT -5
Hi John,
Nice setup as usual....just wondering where the reduction gears themselves came from?? I'm assuming the smaller one is the original one from the starter? But the larger one looks like something from a motorcycle gearbox or similar..!?? Did you just get lucky with the teeth pitch etc..?
Cheers,
Smithy.
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