Wow, then you’ve done a very good job hardening those.
I stopped using epoxy on stators because MG 4228 (Red Insulating Varnish) seems to work almost as well but allow them to cool a little better. If you’re worried about rocks in the though, what you’ve done it better.
Yeah, I was worried that the grit coming in with the road water was accelerating wear on the enamel wires. Second time I’ve had a motor failure of this nature, actually.
MG Chemicals 4228 will absolutely help with water, brine, and grit. Just won’t do much for actual rocks or pebbles if they get in there. It wicks into the windings and makes them a solid mass while also coating the outside. None of them can wiggle around afterward.
That’s good to know, I’m pretty sure epoxy paste didn’t penetrate all the way into the windings
I see what you did there 
After 2 years of too much commuting and not enough maintenance, this board had a few issues piling up. Busted fenders, one motor seizing with debris, the other gear drive flopping loose from ground strikes, and a legstick that had been patched up several times as I replaced failure-prone parts with better designs.
Then a moped rider blew a red light in front of me, going from my left to right, and my board bounced off their rear tire. I bailed no problem and nobody was hurt, but the board went from +15mph to -15mph in no time flat. It must have busted one of the dozens of connections in the flight safe battery system, because power kept cutting in and out while riding after that. So I hung the board up and waited to finish my big inline board before going back in for an overhaul. (I may have also cannibalized the legstick sensor for another build as well)
Changes made:
The battery now has a redundant set of triple 20AWG wires
I dropped this pinion into a garbage can after blowtorching it off, so it got caked in plastic. Thought some of y’all might enjoy the schadenfreude lol
Ready for service.
Hoo boy. After i first built this battery pack, i had issues where it would sometimes loose power after running over a big bump in the road, because the bullet connections in the battery modules would come loose. Adding compression foam underneath the deck to keep them connected fixed that problem, and I thought that’s what was going on here.
But no, it has a very weak throttle response and randomly kicks on the brakes when it hits a bump. Not a power cut problem. I’m guessing it might be a vesc issue? At least with the ADC. I’ll investigate more
ADC is working fine, it was a loose phase wire connection. But after getting a good motor detection and going out for a test ride, the brakes cut out the very first time I applied them hard at speed. They made a loud buzz saw noise, and the machine lost power. So the ESC is probably toast after all. At least, I’m not gonna trust my safety to it.
So let’s see:
I’ve been debating for a while whether I need to fix the 50% of this build that was broken, or save the 50% that worked for a new build. But since more than 50% is defunct I’ll do the inverse of a deck swap: The deck has always belonged on a race board, so I’ll build one around it.
Great news, this board is gonna get a little bit of insanity, as a treat. I’ve got a nice little raceboard lined up to turn this machine into:
This deck looks great with pnummies, but the rear truck needs to be moved up to increase its angle:
I’m taking a break from composites for now, so I’m doing the enclosure in the @glyphiks method, with a 3mm aluminum plate base and 3DP walls. I cut the plate on the CNC plasma cutter I run at work:
Sick!!! Super keen to see how it comes up!
I think its an excellent way to make an enclosure, although mine was pretty heavy!
I’m already going 4WD, so what’s another few hundred grams? It’s still going to be my lightest board lol
Accepting submissions for a 4-word slogan to spray on the enclosure. The deck already has FUCK CARS SKATE HARD, and I have SKATE FAST EAT ASS stickers.
Built not bought bitch!
Old and wonky but paid in full?
Yeah, I know, bad idea.
I think that’s the best possible slogan for a different board somewhere 
Crab Raccoon, perhaps
This would be on the underside correct? Meaning only shown if it’s flipped over?
Consider:
FUCK FUCK FUCK FUCK
If you can read this turn me over.
Alriiiiiiiight so, since my last post here I’ve been in crisis mode due to both my friends’ housing/family situations imploding simultaneously, so our plans to split an apartment moved up from “sometime in the future idk” to “right fucking now”. Took a hot minute, but everyone’s safe & happy now, and I finally got my own little room in NJ, with all my tools and supplies set up at a nice little work station. Behold, the second or third finest furniture that money can buy at IKEA:
So! The build is back on, and it’s coming right on the heels of TEF1 Atlantic announcing it’s location also in NJ, so I’ve got a 2 month deadline to build and shake down this board.
Coming back to the project with fresh eyes, I’m seeing that there’s a couple clearance problems with the trucks and the 6" cyclones that I could solve by just chopping bits of the deck off, but I know I won’t be happy with the results because:
So a good and proper solution is really going to involve lifting the axles, dropping the deck, extending the nose and tail, and top mounting the trucks. I want to raise everything by 25mm and drop the deck back down by 40mm, so I’m prescribing a dose of 8" nova tires and laser cut steel drop brackets. 90% of patients report a 47" wheelbase with 35/15 angles and 33 degrees of lean within 2 weeks:
I started setting up the chain drive components I’ve been sitting on, starting with laser cut stainless sprockets glued to 6900 flange bearings and a printed spacer:
Custom mounts and MBS clamps:
The setup will be 14:50T #25 chain, I’m thinking that gearing for 45mph is the way to go for the TEF1 track.
I also got the enclosure glued together, with the aluminum plate painted up nice and pretty:
Which means the remaining items are the battery build and the drop brackets. Stretch goals are a simple relocation of the legstick to gain back a little standing platform, seeing if I can mount my steering damper, and to print some footstops that do normal footstop things, but also act as stops for my heels and toes to prevent me from sliding around. I’m going to avoid using a binding if possible, don’t wanna risk another crash like the one I had at Electrify expo.
