how to build a homemade electric motor

Usually, when you think of Hybrids or electric vehicles, you think of tiny, two seater geek-mobiles or soccer moms in awkward chunky cars with cup holders full of pumpkin spice latte.

All that remains is as many weeks of refinement as you care to deploy. A 1kWh lithium battery is roughly 20Ah at 48V – about the same amount of energy held in an 80Ah car battery at a quarter of the weight. Olly Epsom is a chartered engineer specialising in renewable energy, particularly wave power. The lathed spline screwed nicely into the 8mm female thread on the motor shaft, and a lock-nut completed the union.

Finally I located a cheap electric bike twist-grip throttle for around £10 on ebay.

This will bring the total budget to around £500-£600. I used a multimeter and figured it out for myself. I removed everything north of the driveshaft housing and re-sold those components for £5. How much is enough for a deposit when buying a boat. This is the main section of the motor. There are various battery packs on ebay and Alibaba. This will give you something solid to wrap your coil around.

Original cooling impeller can be discarded.

This should not daunt you as they are easily available.

Because I wanted a system that was more powerful than the cheap trolling motors, but much cheaper than equivalent commercial units (an equivalent ePropulsion Spirit currently retails at around £1,500). It is possible to make an electric motor go backwards as well as forwards but be cautious doing this on an engine which originally had no reverse because the gears won’t be designed to operate backwards and there won’t be a thrust bearing to keep cogs in check. At the bare minimum you’ll need a good toolkit, hacksaw, files, drills, power/battery drill, lighting, workbench, soldering iron and good multimeter. To connect the motor to the driveshaft I asked a friend with a lathe to turn down the end of the approx 11mm spline and put an 8mm thread on it. There may be other reasons to embark on such a project, and if so, fill your boots. Hopefully plug/socket from the hall sensors on the motor will match the plug/socket on the controller hall sensor line, otherwise go figure it out. I decided on a brushless DC motor because they are generally reliable and don’t require maintenance of brushes.

These old engines had very high specification mechanical components and the gearbox in particular was in excellent condition. Download Project. 3. Usually red and black (5V and ground) and green, yellow and blue (which take the signals from the three hall sensors in the motor). at home.

Because I have longer-term aims of making the system fully remote controlled (essentially a drone, perhaps for wildlife photography), and for that I needed complete mastery of the control system, which is achievable if I build it myself. The main disadvantage of this, however, is that every time the motor is removed it brings the driveshaft with it, which makes reassembly quite a faff. Basically, electric conversion involves removing the entire internal combustion engine from a vehicle, installing an electric motor in its place, and also adding a large bank of batteries. Materials. Now is the moment of truth. It will almost always be possible to buy a petrol outboard for less.

Watch this space for part 2: programming the motor’s electronic controls. One such arrangement is shown in the schematic diagram (above) of the simplest possible control system.

Above this, in place of the engine would be an electric motor, directly coupled to the driveshaft.

Likewise battery packs at 48V were more numerous. I also had to learn how to code the software.

All have a built-in charge controller, and all require an external mains charger.

To keep myself occupied at home, alone, over the long nights of a Scottish winter (over previous winters I’ve constructed a navigation system, an autopilot and solar water heaters). To embark on a project like this requires a basic knowledge of electronics and mechanics, but should be within reach of most practical people with a willingness to learn.

You’re now able to electrically connect the components and conduct a simple test. And there's more for owners of sail or power: Engine mounts, bilge alarms, navigation lights and interpreting weather forecasts. Arduinos are tiny programmable computers with analogue and digital inputs and outputs. And the inevitable problems that emerge, some of which I’ll detail in my next article. I had the rough design in my head after an evening of research online. That said, the better equipped your workshop the better the finished product is going to be and, in addition, costs will reduce because I had to have a few parts manufactured that could be made at home in a good enough workshop.

So why did I do it? Connect the sensor plug on the controller to the sensor socket on the motor. These are usually coloured green, yellow and blue.

It cost me more in fuel to collect it.

Connect the red wire on the throttle to 5V (usually available on one of the numerous outputs of the motor controller), the black wire on the throttle controller to ground on the motor controller, and the third wire (could be any colour) to the speed input of the controller, which could also be any colour. Plus weeks of your time. The motor was around £100, the speed controller another £40.

2. 2. The motor, control systems and batteries are the main components, but figure on another £100-£200 to cover enclosures, transition pieces, wire, switches, connectors, and, of course, things going up in smoke.

I then noticed the Nextion range of graphical touch screen displays, which retail at around £16 for a 3.2in version.

Connect the battery positive and negative to the motor controller positive and negative, and give the throttle a twist.

With the learning and setbacks the project took me about six weeks of evenings. But I am single (hard to believe I know!)

In addition there was a far wider range of motors available at 48V.

Find out how to make a simple electric motor.

The battery would be separately mounted and connected via flexible electric cable. The vendor also sold me a ‘matched’ charger which subsequently caught fire. Get every issue of PBO on Android, iPhone, iPad or desktop. Whilst not as rugged or tough I was seduced by their sexy colour screens, with the ability to display multiple dials, graphs and buttons. Finding which wire does what in a manual-free wasteland is very challenging. Subject. with a central hole of 10mm.

[1] X Trustworthy Source Science Buddies Expert-sourced database of science projects, explanations, and educational material Go to source Batteries of this capacity range from £200-300 depending on vendor, delivery charges and taxes. The downside to lithium-ion is the cost.

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