This part went okay but again, it ended up like this:
I’m gonna try a third time to get some decent wire routing.
Starting with adding length to the phase wires so I can eliminate another unnecessary connection point.
Before:
After:
Next, I think I’m going to run them out the sides in a channel rather than out the back squished by the enclosure, it should give them more room to articulate away from the ground.
Like this:
Since I’m trying to keep everything flat against the gasket now I also need to cut a wire channel for the metr GPS, and of course, more silicone.
The channel was a bit bigger than necessary but I think the silicone should solve any issues the oversized channel would normally cause.
Now onto the sensors.
Same idea as before, obviously still inspired, nay impelled by mistfall from @BenjaminF
Same plan as before to go absolutely buck wild on the strain relief.
JST connectors:
Clipped and soldered:
Now, @BenjaminF recommends using 2 layers of heat shrink under the shroud, my 24awg wire+doubled up heat shrink won’t fit through the shroud, I’m sacrificing the second layer of heat shrink in favor of silicone+being able to fit the cable shroud.
Just the single layer of heat shrink is already pretty tight.
With silicone and cable shroud:
Next up is the pulley issue, for context; the pullies that are currently on there are installed by the factory and for some reason they use some kinda epoxy in the head for the grub screws so they can’t be removed without drilling, so drilling it is.
Unfortunately, as a certified dummy, I didn’t actually measure my motor shaft, I measured the flat spot and just assumed it was an 8mm shaft. That was silly.
Since I had to drill out the grub screws to get the pullies off, I can’t really reuse those unless I tap new threads and I personally, can’t be bothered to do all that.
Instead I’ll steal them from my Spare parts board
The pullies on my spare parts board had the same issue but I got somebody from a local machine shop to drill out and tap those with slightly bigger threads. Those can actually be removed and installed with an Allen key and some loctite, this way once the new pullies arrive I can install them much easier.
Still gotta wait another like 2 weeks for those pullies though.
Sadly motor detection keeps timing out even with sensors disconnected. I suspect I may have messed up when soldering new wires to the PCB on the DV4S?
Most of them look good to me (despite the silicone, probably should’ve used the MG chemicals 419D I had instead) but I’d really appreciate a second opinion.
I wasn’t able to remove all the silicone in the time I have to work on this today but is there anything visibly wrong with these solder joints that could cause motor detection to time out?
A couple other weird marks/spots on the PCB:
