John Allen's 1994 Celica Part 5.mov

Overhaul of Electric Motor, Netgain Warp 9
Electric Vehicle conversion. Re do of 1994 Toyota Celica from Lead acid batteries to LiFePo4 batteries

Category:

Autos & Vehicles

Tags:

• EV Conversion
• John Allen
• Electric Vehicle
• Electric Car
• Warp 9 motor
• EVTV.ME

[tandalakubwa]

George,

I am avoiding all things silicone. The motor is sounding quite nice now that the brushes are settling in. I would love to get a set of Helwig brushes. Just let me know when you can get them to me, cost etc.

John

[unixtm]

John, Glad to see you using the file - this is a trick I normally only mention to serious racers, but everyone could benefit by it... I imagine the motor quieted down quite a bit as the motor ran. I'm checking on a new set of brushes for you...

George

[unixtm]

John, You did a good job of demonstrating how to perform maintenance on the brushes. I would suggest you DO NOT pull on the shunt wires (lead wires) they can fairly easily be pulled out of the brushes. Lift the brush springs and "gently" pull on the brush shunt wires to the point where the spring can be released against the side of the brush. This will ensure the brushes stay in the same slot and make it easy to disassemble and replace.

[unixtm]

John,

One thing I forgot to mention is that NO SILICONE (even silicone fumes) should be used around brushed DC motors! If the silicone is completely cured, then it is alright, but the silicone and its fumes will destroy the brush bonding material - this is from Tom Brunka...

[unixtm]

John, (I hate this character limit in responses..) Tom indicated there was some trailing edge issues with the brushes as well. This problem could be addressed by changing the timing to meet your power levels, or changing brushes would help dramatically (and probably with he noise as well). We need to get off the old-style generic brushes and onto the dual-wafer, split-top brushes from Helwig! Contact me about this ASAP!

George

[unixtm]

John, I just talked with Tom Brunka from Helwig-Carbon. He indicated some things that could cause the squeaking. First, he said it was necessary to use the garnet paper a second time after you used the razor on the slots to remove burrs that he felt could be causing the noise. He also wanted to verify that the brushes weren't installed backwards, as that would cause noise (and brush damage). Can you send me an Email at ghamstra AT go-ev.com so we can resolve this noise problem?

[unixtm]

John, the brushes you have are fine and look very well seated - be sure they go back into the exact spot they came from! The "shim" is actually a "wavy washer" used to ensure there is pressure against the bearing. I think Tom Brunka referred to emery cloth. I've asked him to watch and comment. Your motor is a noisy one, but we'll work it out! Those are the very old style brushes, but the Helwig dual wafer brushes will fit right in. Tom will probably suggest H60 grade - insulated leads..

George