All in a days work.

[John Stevenson]

Well in a day anyway, work may not come into it.

So this morning bright and early [ well for me anyway ] I set out for work, the reverse of the 34 steps I had taken the night before when they dropped 25 motors on me for conversion to a smaller frame setup [ shorten shaft, weld keyway up, turn down from 19mm to 14mm and re-keyway, then slot the mounting holes in the end cover x 25 times - booooring

So 33 steps later and I fell over this pile of end covers, brake housings a rotor and a weird circular bit on the floor outside the door. Opens up and starts to get fire going, phone rings and this Herbert says did you find my parts ? Find them I bloody well fell all my length over them. I can see what's wrong with them except for the circular bit.

That's an impeller that goes on the long rotor.

Wot ?

Speaking slowly because it's early " Goes on the long rotor "

"Can't do the holes too big"

"It's worn"

Worn ??????????



That's about 38mm or 1 1/2"



The shaft is 24mm or a tad under 1"

Now I have seen worm things before but the shaft isn't that bad compared to the bore of the impeller, most of the original keyway is still there on the shaft but totally missing from the bore. Add to this two cracks into the bore from the webs and it's cast iron.

Phone goes again, any chance of it back for dinner ? Sure, but note I never said which dinner <g>

First off weld the cracks up then stiff in outside jaws on 3 jaw chuck and bore the hole out, it went out to 42mm before it cleaned up, that's about 1- 5/8".
Machined a slug up, pressed it in, loctited it and pinned it then bored it out to 24mm and stuck a 8mm keyway in.



Rotor was straight forward so won't go into that.

Leave all the rest they weren't important, then onto the motors.



That's what 25 rotors look like ready to box up and go back first thing in the morning.

I HATE ELECTRIC MOTORS.....................................
.

[SDL]

Are the bigger holes around the edge for balancing or some other function?

Does it need balancing? shouldn't think so from the size of the worm bore

Steve Larner

[Bill in Ky]

Nice work sir!

[ammcoman2]

I wager that if you botched a few you wouldn't get nearly as much business.

The fact is that you are just too darn good at your job. Or that nobody in the area is so thorough. If you want to slow down a bit you know what to do about pricing.

Keep up the good work - and the posts. I sure learn a lot from them, even though I have done a few DC motors and auto generators.

Geoff

[ammcoman2]

Forgot to ask about the slug - did you use a roll pin or a solid one to pin it to the impeller?

Geoff

[John Stevenson]

Yes spotted the balancing holes but no idea what this is off, never seen one like it before.

Anyway it's all stuffed up now I have splatted 4# of nickel weld all over it , the motor people have very good electronic balancing gear, I'll just mention it to them and then it's up to them.

The slug was drilled and tapped in three places to line up with the spokes and three 6mm allen grub screws fitted half in the bush, half in the impeller.

It's not so much being good as being quick. OK this one was a special but many jobs are borderline whether to repair or replace and if you are too dear you loose out.
What's better getting a regular small mouth full or a big bite and choke ?
Some of the jobs may sound cheap but even the small ones go for one hours minimum labour and if you can do a couple per hour it's not so bad.

That rotor in the picture I can easily do 3 or 4 in an hour because I'm geared up for it.
Quick change tool holders, 4 MiG's all with different wire and all manifolded to the same bottles, Plenty of different chucks and steadies, Keyway milling cutters set up in holders, DRO's on machines and many more time saving tools and fixtures.

[motorworks]

"shorten shaft, weld keyway up, turn down from 19mm to 14mm and re-keyway, then slot the mounting holes in the end cover x 25 times"

John
Just wondering...
I do the same regularly, but I get "standard" motors and have to make them "metric"!

If you are shortening the shaft and turn from 19 to 14 why fill in the old key slot?
Won't the slot machine away.The key in 19-6 is 3.6 deep
or perhaps these are woodruff keys?

"What's better getting a regular small mouth full or a big bite and choke ?"

around here it's:
Shear for a life-time, butcher once!

[John Stevenson]

If you are shortening the shaft and turn from 19 to 14 why fill in the old key slot?
Won't the slot machine away.The key in 19-6 is 3.6 deep
or perhaps these are woodruff keys?

All my tables give 6mm key as 3.5 deep not 3.6.
So 3.5mm deep on a radius of 9.5 so that leaves 6.0

6.0 x 2 is 12.0 that's under 14 and leave a witness mark in the shaft.
can't pick it up and use that because 14mm is on 5mm key.

[motorworks]

Yes
You are Right John
It will leave a mark!

Engineers Black Book says 3.6 max....
I will be looking for a refund in the AM

[Frank Ford]

John -

I always enjoy seeing your repair projects - there's so much to learn.

Having spent better than four decades doing repairs for a living, I sure have those I get to do more often than I'd like, too, but they pay the bills: