Friday, October 31, 2014

Upgrading (up-sizing) motor's phase wires, from 14AWG to 12AWG,

Having some phase/signal wires stripped (again) by not fastening them well enough, I had to open up the motor and re-solder/attach them. :(

So I decided to upgrade the phase wires while I'm at it from what seems like 14AWG to 12AWG high quality Turnigy wires.


However, lo and behold, the channel is way to thin to allow three such phase wires due to their very thick silicon wrapping.


What to do? Replace the thick coating of course, by stripping the silicon and slipping a shrink tube!


The yellow wire on the right is the stock wire. The red wire on the left is the 12AWG turnigy wire with the silicon wrapping, and the wire in the middle is the turnigy wire, bare with only the shrink tube. See that it's beefier than the yellow.

The next step is mounting the hub motor plate back without causing damage to the coating, since it's a pretty tight fit as it is. BTW, for this particular job and for opening up hub motors in general, do yourself a favor and cough up some $$$ and get a gear-puller. If I knew how easy it is to get the plate off using a gear puller I had gotten one from day one!

Let's begin. Start by just inserting the motor axle's narrow part through the plaate's bearing...


Examine the fit more closely, see that no one is hurt...


And continue to press until it's mounted all the way.

Now make sure the moving part does not touch the wires (here I used a zip tie) since it will strip them as one point or another (which is what happened last time).


And we're good :)

If you're use the same color wire for several other wires, be damn sure to mark them beforehand. I've always kept that rule and never had to re-fix anything, which would be hellish.