Friday's work: Shaft extension (version 2), keying and preliminary frame production!

CAD design of the winch - and our "banner".

Very successful day @ the workshop!
First off we managed to create new key "holes" on the transmission parts that fit on the drive shaft. (Previously: transmission parts were made for 3/4" shafts and not 20mm shafts - in the process of modding them to 20mm we had to sacrifice the original key tooth). Now with the mod'ed transmission parts we had to create a 2.5x5mm "trench" so that a key (square long rod) could be used to connect the shaft to the transmission parts. Great success! We basically used a 5 mm thick long metal piece with teeth on one side and forced it through the hole with a hydraulic press. (Pictures to come). The teeth would cut away a perfect 5 mm thick path for the keys to fit in.

Secondly we mastered out a new design for the shaft extension:
As mentioned earlier the first engine shaft extension was not successful. The steel rod used was not machined precise enough for our use. It was "oval" creating strong vibrational forces due to the off-center nature. However we now machined our own 20mm shaft extension on the lathe. Started off with a 25 mm steel rod and worked our way down to 20.00 mm. Originally we created M8 threads on each side of the extension; one side to fasten it to the original shaft (with a short threaded rod) and the other to hold the transmission parts in place. This time however, to improve, instead of creating bolt thread holes on each side, we decided to drill straight through the shaft extension and use a center bolt, going straight through the extension, to hold it in place. This being better because the center bolt will lie perfectly against the extension piece therefore having better radial support. It also eliminates the problem of off-axis nature we saw with the previous extension. Problem solved - inshallah.

Those were they main two features of the day - but we also started constructing the frame. We got to test out the welding equipment which was awesome! Built the base of the frame and added the plate where the engine is going to be placed.

What a day! hehe (everything is in relative context!!)

First weld of the project!

Base part of the winch frame finished.

Adding the base attactment plate for the engine.

Banana, sandwhich and pepsi.