I am now finishing up my halls on my 270kv 63mm motor and will be doing some testing with my vesc so thought I would make a thread explaining how I made it. It was ridiculously frustrating to finish but seems to hold up well. It is all put together now but I will explain how I did it.
The main problem is no wiring will fit, even as small as 30awg, because the slot for the main wires is only meant for the size of the motor wiring.
So I am using headphone wiring. This wiring is paint shielded so it will not cross connections even though there is no shielding.
The hall sensors will not fit between the spaces so the stator need to be drilled. This is frustrating since the metal is tough to grind. I used a dremel and carbon bit and it wound up slipping once and skipped over the wiring damaging three wires. The motor still runs fine though.
I used some e6000 glue to hold the wires in place. Instead of using epoxy to hold the sensors I wrapped some kaptan tape around the stator then used super glue and some paper tape to keep it from unraveling.
I fed all the wires thru a small silicone tube so it will compress along with the main wires and keep them safe.
Using more headphone cable I made a mini usb cable that connects to the jst cable. This plugs into a mini usb board I found on ebay.
Going to put my scooter back together this weekend and do some tests. Very excited to see the low end power with sensors installed.
The main problem is no wiring will fit, even as small as 30awg, because the slot for the main wires is only meant for the size of the motor wiring.
So I am using headphone wiring. This wiring is paint shielded so it will not cross connections even though there is no shielding.
The hall sensors will not fit between the spaces so the stator need to be drilled. This is frustrating since the metal is tough to grind. I used a dremel and carbon bit and it wound up slipping once and skipped over the wiring damaging three wires. The motor still runs fine though.
I used some e6000 glue to hold the wires in place. Instead of using epoxy to hold the sensors I wrapped some kaptan tape around the stator then used super glue and some paper tape to keep it from unraveling.
I fed all the wires thru a small silicone tube so it will compress along with the main wires and keep them safe.
Using more headphone cable I made a mini usb cable that connects to the jst cable. This plugs into a mini usb board I found on ebay.
Going to put my scooter back together this weekend and do some tests. Very excited to see the low end power with sensors installed.