Today’s issue: ESK8CON Prep
Wait, esk8con already happened! Like a month ago!
Yeahh… took me a minute to get to this writeup 
Front box revamp
As mentioned before, I avoid doing anything with the front box it if I don’t have to.
However, It reached the point where it basically needed all of it’s parts repaired or replaced, so my hand was forced into doing something.
Off they come!
First step, bend the metal back into shape
Return of the hodgepodge metal break
“But won’t it just get bent back out of shape again?”
Good question, metaphorical reader.
New footstop
In the current design, there’s nothing to take transverse (side to side) loads on the box.
When I first installed the 3D printed footstop, it was designed to be a barrier between my feet and the G300s, not a structural member. Because of this, it was only 1.2mm thick.
Engineering Forces Tangent
It’s basically a 4-bar mechanism(where the pivots are at the corners of the sheet metal), so it’s not surprising that it gets bent out of shape. (This is why we use diagonal pieces and triangles when designing buildings and whatnot)
This is reflected in how the part breaks. It broke at the layer lines of the 3D print, but only between where it connects to the box
What happens is it takes up a transverse load, but it’s not strong enough to resist it. This shear load breaks the middle of it into a bunch of little bars, which “slide” relative to eachother, letting it part flex and deform, reliving the stress. (This is represented really well by the permeant deformation in the picture)
I printed a new beefy version that’s 4mm thick and solid plastic. It should definitely be able to take the transverse loads now.
I have the slots for the sides extending into the 4mm front so I don’t give up any more valuable deck space, and there shouldn’t be much force going through that section of the part. Most of the stress should flow through/around the interior fillet.
New Spine clamp
This part clamps the box to the frame of the board, transferring all the forces directly to the frame instead of going through the sheet metal deck.
Fixed it.
New nut retention
While I was re-assembling, I took @BenjaminF’s suggestion of a captive nut plate. This made reassembly massively easier, thanks for the suggestion dude!
If you were eagle-eyed, you migh’tve spotted them it in a earlier photo.
All of these improvements means the box is much stronger then it was before. 
Tires
I wore through my front BRPs, but I didn’t have any replacements on-hand (until receiving new set from @MoeStooge at esk8con).
@HAIRYMANJACK had a spare pair of wides that he let me use. Ended up having enough tread to race on them at esk8con, even! Thanks dude.
^Artwork curtesy of @Lyfe_Of_Jimmy, feat. Reggie Thomas
Busted Batteries
Woke up for work one morning, and felt the need to check the battery in my stooge.
that’s… suboptimal
guess I’m WFH today. I started discharging the packs 4 at a time using my iCharger x12 at 50W. Took all day to bring them all down below 4.2.
I definitely did some damage overcharging them like this. They’re all slightly puffed now, and their internal resistances shot up. (When they were new IR was 0.1~0.2mOhm)
I removed the two packs that now had the dead p-group, labeled 'em appropriately.
I then drove to San Diego for our weekly track night and did 8 miles on track 
So I’m back to running on 12s for the time being, unfortunately. I could buy two replacements for the dead p-group packs, but I’d be warry of running new packs in series with damaged ones.
Fortunately, I still had the old balance harness and hardware from before I upgraded to 16s… Popped that back in how it was, and I’m still able to charge without opening up my bellypan, but I’m back to charging with my iCharger x12. I’m waiting to receive a zBMS in the mail, the only BMS that can fit in the restrictive space.
Once I get it installed, it’ll let me go back to charging with a single plug. Can’t wait.
Brake light
(go to the quote to see the video I previously posted, pretty happy with the aesthetics)
Aspiring to make these code updates before eks8con, I plugged in the Arduino to my computer. I proceeded to corrupt it, or something, idek, it didn’t even register in device manager after I tried to upload code.
These things can happen with arduinos. Though the magic of buying two of them, I had a spare microcontroller. While I was swapping it out, I figured I could make things better. The first one was just a quick prototype- it was little more then a microcontroller with some wires soldered to it(and covered in heatshrink).
So I spent a few hours making a more proper breakout using perfboard, connectors, and crimping matching connectors onto the harness inside the board. Much neater.
Unfortunately, even though the pinout was the same, it’s unable to register the PWM signal from the receiver. 
Esk8con was growing closer, so I cut my losses and figure it out later. I put kapton tape over the newly crimped connectors on the board and moved on.
It’s more of a break light, amiright?
Stickers
Honestly, I’ve unexpectantly grown attached to my silver bellypan.
However, it was a bit plain, so I covered it in stickers at 2am before leaving for esk8con
Shoutout to all of the incredible, awesome people that makes this sport fun, both on and off the track
Photos from @Lyfe_Of_Jimmy and @MarioChacon
Packed and ready for esk8con
And to think I thought I could fit a second person and stuff in here
To be continued in a future edition…