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Before the shaft arrived we had the customer send the raw dimensions and produced this model.
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This is the armature assembly as it arrived.
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Here you can see the balancing epoxy putty that was used when the armature was dynamically balanced.
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Pulling the lower bearing from the shaft.
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With the bearing removed you can see the puller clearance/step.
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This is the arrangement for pulling the upper (DE) bearing.
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This is the drive end of the shaft with the bearing removed.
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This is the measurement and orientation for the armature core on the shaft.
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Press the armature core off the shaft. Even though the core is held in place with just a knurled surface it took a few tons to press it off.
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This is the bare motor shaft. Now I can take all the required measurements.
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Started by cutting a length of 1018 cold rolled and center drilling it.
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Mounted the shaft between centers using a constant face driver and a live center. The factory shaft was done out of 1.1875 material. I could only source 1.25 so I'll have to turn it down.
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Turned down to diameter.
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Knurled the shaft. The knurling will hold the core in place.
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Flipped the shaft and machined the lower end of the shaft.
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Flipped the shaft back and machined the first bearing step.
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This is the upper 5/8 shaft portion.
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Machined the threaded portion along with the clearance relief groove.
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Added the 7/16-20 thread.
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This is the new shaft along side the original. By making a new shaft we've changed a 56C into a 56J motor.
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Pressing the core back onto the shaft. Note that I'm using pipe to protect the shaft.
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Pressed the bearing on.
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This is the completed rotor assembly.
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