Handwound Brushless Outrunner.

[Donziikid]

Went to a motor winding ceminar for my local flight club and wound a brushless outrunner motor with 18AWG wire. It's a 9-pole armature with 12-neodynium magnets with 6-winds per pole. It pulls approximatly 55amps at full load (11.1 volts off a constant voltage) and slings a Acer Wing at 106mph. Deffinetly not for use in foamies; it'd rip it to shreds because has a so much torque.

Being that I already had experience winding 130-size armatures I didn't really learn much but it was still a great experience to be there and help some of the older gentlemen (40-70 years of age) see what they were doing. I'd gladly do it again just to build another rocket motor. :lol:

http://i73.photobucket.com/albums/i206/Donziikid/GSR/Custom%20Wound%20Brushless-Outrunner/DSC_0519.jpg
http://i73.photobucket.com/albums/i206/Donziikid/GSR/Custom%20Wound%20Brushless-Outrunner/DSC_0526.jpg

[xmodificationer]

that is freaking sweet! Man that thing would rip, IN A XMOD!

[2wdpancar]

Dang, I would love to rewind one.
I think I've seen 50 amp ESC's before, but they are expensive..
:nodno:

[REDisFASTER]

And Donzii is how old? Man, we've got a lot of talented members here!

[Donziikid]

Dang, I would love to rewind one.
I think I've seen 50 amp ESC's before, but they are expensive..
:nodno:

It's not rewound, totally fresh start. This was totally custom and one off. The bell is designed by Komodo and the other bits and pieces are off of scrap brushless outrunner motors. I had to glue the rotor to the rotor plate and then do everything else, lol. If I purchase another kit I'll take a step by step picture log. ;)

50amp is tiny. :lol: Ever seen the Castle Creations Pheonix 180?

And Donzii is how old? Man, we've got a lot of talented members here!

15. :lol:

that is freaking sweet! Man that thing would rip, IN A XMOD!

You may see something similar in the near future. Maybe.. ;)

[Sweed]

And Donzii is how old?

He's just a wee tad-pole...

[2wdpancar]

Dang, hmmm is there a place where you can purchase the arm things?
Sorry, I'm new to the whole BL motor..:lol:
btw, you have a PM.:)

[Donziikid]

You have a reply to that PM. ;)

The can is a replacement part bought from: Komodohobby.com (www.komodohobby.com). However, you could buy the whole kit which comes with wire, bearings, can, arms, magnets, etc. from ~$25 and wind it yourself. The problem with that is you need to buy a magnet spacer, or fabricate one yourself. Also, these do not come with directions. You'd have to find them online or figure it out yourself; brushless motors are a lot more complicated than a 130-brushed. ;)

The wire that comes in the kit is relativly small, around 26AWG; so it does not supply as much power. I believe a member of our group wound one with the stock wiring and only got 27amps and only clocked in at 40mph. The wire means everything, and the upgraded bearings/lubricate and aluminum in mine does make a difference. :lol:

[Donziikid]

40 grams all together.

More pictures:
http://i73.photobucket.com/albums/i206/Donziikid/GSR/Custom%20Wound%20Brushless-Outrunner/DSC_0528.jpg
http://i73.photobucket.com/albums/i206/Donziikid/GSR/Custom%20Wound%20Brushless-Outrunner/DSC_0529.jpg
http://i73.photobucket.com/albums/i206/Donziikid/GSR/Custom%20Wound%20Brushless-Outrunner/DSC_0530.jpg
http://i73.photobucket.com/albums/i206/Donziikid/GSR/Custom%20Wound%20Brushless-Outrunner/DSC_0554.jpg

[RedSXmodder]

!!!!!!!!!!!!!

I was just going to do this to my Rimfire yesterday. Not really sure on how to get the outrunner apart right now. That thing'll have an arse-load of torque when I'm through with it...

Later,
RedSXmodder

[Donziikid]

Hopefully you know how to do it properly; it's a lot different than a 130 can motor in my opinion.

Also, I suggest a smaller AWG. This 18AWG was a pain to get inbetween the rotors. I literally had to thread and needle the wire through the tiny spaces because the sixth wind on each arm took up too much room and butted into the space for the next arm. They're as tight as can be, too. :lol:

[RedSXmodder]

24awg maybe? I'll just redo it like I unwound it, and it should work. Whats the technique?

Later,
RedSXmodder

[Donziikid]

Y-Pattern.

On a nine-pole armature:
http://i73.photobucket.com/albums/i206/Donziikid/RedSXmodder/Pattern.jpg

You wind in a clockwise pattern starting from the inside (closest to the middle) and wind towards the outside. You will notice from the pictures that the extra winding going from one pole to another gets tucked as close to the shaft (the part the can spins on) as possible and you start to wind again in a clockwise pattern with the same amount of winds.

If you do it and have any questions don't hesitate to PM me. ;)

[RedSXmodder]

Easy Peasy lemon squeezy ;)

JK. I'll probably have to mark on the poles 1-2-3-4 and so on...

Later,
RedSXmodder

[Donziikid]

Easy Peasy lemon squeezy ;)

JK. I'll probably have to mark on the poles 1-2-3-4 and so on...

Later,
RedSXmodder

Sharpie is your best friend. I marked each pole 1-2-3-4-etc and even marked my magnets to dictate which ones were north and which ones were south. Unlike a 130 there are 12 magnets in this can and I had to install them all with CA glue and hemostats. Lol.

Everything you see in those pictures I had to do by hand. Nothing was done from the factory. I had to wind each pole, I had to install and glue the magnets in (tricky little things at only 1.5mm, especially when they're neodyniums), strip and solder everything, heatshrink everything, install the bullet plugs. All in all it was about a four hour process for just one motor. Heck of a lot slower than a machine that can spit these things out at +5/hour. :p