- PROBLEM - Wire routing from motors to enclosure
Parts: Flipsky 6374 sensored x2, loopkey, 5.5x2.1 charging port, LED strips x2
More specifically, routing wires from inside to outside the enclosure AND maintaining some level of water resistance (and full functionality) takes carefully planning.
System design drivers:
- Maximum water/weather resistance
- Some level of maintainability (i.e. no permanent mounting)
- Smart choices for charge port, loop key, LED positioning for ergonomics & usability
- Reduce unnecessary wire length inside the enclosure to converse space
- System longevity
- SOLUTION -
Custom tunnel risers to allow cleaner routing
I started by designing and printing an XT90 mount in PLA that attached via the existing truck screw.
After some tweaks, I incorporated it into a riser pad. The 6mm thick pad included a diagonal wire channel for a deck-top mounted charge port. (mid print here)
Final version, in 100% infill black PETG, cleaned up the design by sticking with a more simple central tunnel. This tunnel goes the full length, allowing the charge port wiring to route through the large central hole, as well as LED wiring from the end of the truck. I also closed off the slit in the XT90 mount - it now requires the connector to be soldered around the mount, but it makes for a more robust and visually pleasing design.
Mock mounting shows the locations, and the tunnel.
The generous 10mm dia tunnel should allow two sets of small gauge wire.
Files attached for anyone’s use:
Baseplate Tunnel Riser - 6mm v2.stl (420.2 KB)
Baseplate Tunnel Riser - 6mm v2.step (75.8 KB)
Baseplate Tunnel Riser with XT90 Mount - v2.step (503.2 KB)
Baseplate Tunnel Riser with XT90 Mount - v2.stl (1.2 MB)
Loopkey Holder - v2.step (364.9 KB)
Loopkey Holder - v2.stl (1.3 MB)
5/19/2021 Update
I ended up scrapping the rear truck baseplate mounted loopkey design, because I needed the room for wire routing.
Taking advantage of @ducktaperules cable riser from his Double Trouble build (that he so nicely provided the files for):
I repurposed it will some modifications. It allows for routing:
- qty 2 x MR60 connectors, with 6 phase wires
- qty 2 x JST connectorsm, with sensor wires
-and now, additionally- - center charge port wiring
- 22awg-4 conductor LED wiring pass through
- loop on either side for a 180deg route for all motor wires
- MR60 “lids”
I also modified the front tunnel riser (aka Power Riser) a bit for fun:
Also with a 22-4 cable pass through.
With so many lofts, radii, extrusions, planes, etc the MR60JST riser was not my finest CAD work. Eventually I had to stop fine tuning and just print it. It required a small amount of dremeling afterward, but otherwise it worked.
Filled all connections with neutral cure silicone sealant to be safe. It’s a very tight fit in there. Once the trucks are mounted on top of the riser, nothing’s going nowhere. Silicone wires allow for pretty tight bend radius.
