We have got to use the new Dremel, it turns out that Jane manages to cut about 10x as much as me with each cutting disc. This is the first of two identical front panels. It needs 5 slots cutting in it (4 for motor bolts, 1 for the motor shaft) so that the motor height can be adjusted to tension the drive belt. It also needs a hole for the drive shaft and 2 holes to attach the bearing for the drive shaft.
At this point on Thursday evening we had a bit of a production line going. I was drilling the bolt holes in the lengths of stainless steel angle that make the frame around the end plates. Jane continues to cut the slots in the end plate.
Initially the drilling and cutting were not hopeless. Each drill bit was only lasting a little longer than one hole. Since then the casting of the support for my drill press platform broke and I have bought some WD40 cutting oil. With my big old hand drill and the cutting oil my latest drill bit has lasted for about 10 holes.
The dremel is slow but clean and precise for cutting the sheets.
I’ve used my cross cut mitre saw for cutting the lengths of angle stainless steel which is pushing it pretty hard, it needs a new blade, but it is a big time saver compared to cutting them by hand.
Top and bottom frames for both front and back end plates. The two with extra bolt holes in the middle are the tops, the holes are used for bolts that lift the motor in the slots.
This shows a first dry fit of the front motor panel. The top pulley is attached to the motor drive shaft. The lower pulley to the output shaft that will connect (behind the motor frame to the propeller shaft.
At this point we have 2 slots ready for finishing (which will make sure the alignment is close to perfect). The central oval is for the motor drive shaft and it’s surround, it is about 50% cut so far.
This is the front end of the motor showing the drive shaft and raised surround that will come through the oval.
This is the lifting mechanism for the motor so that the belt can be tensioned.
So while it is quite time consuming it does feel like we have what we need to get this done.