Converting a Starter Motor into a BLDC Motor

In this video I convert a starter motor into a powerful BLDC bike motor.

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[nerbpsj]

For a no motor designer you did EXTREMELY impressive. But let me tell you a couple of things:
Flat magnets, though can reduce torque up to 10%, won't make that much of a difference like you had. The motor should have pulled if everything else is ok.
- Check if hall effect sensors are deep enough in the stator core so they are in front of the rotor magnets even if there is some misalignment;
- check if the hall combination is correct, there are two of them which will spin the motor but one will produce torque;
- double check magnet polarity.

[Aaron]

Used to work in a shop running mills and lathes that did prototype work. That was a good deal. I think the JB weld putty is what threw your DIY rotor off, possibly the epoxy as well. You really need non-ferrous epoxies so you don't throw off the magnetic fields. Convert to belt drive or put a chain tensioner on the bike as well.

[Atech]

Just a note, a ZF steering rack from bmw, mercedes etc. have very powerful servo motor (bldc) and can be bought very cheaply.

[charlesstaton]

I was afraid the comments section was going to be a cesspit, just a bunch of "congratulations you just built a BLDC motor out of a BLDC motor" and "wow, so pointless." I am glad to see that I was wrong and all the comments so far are positive. This is a really cool project and a great learning experience. Thank you for sharing about JY Stator, I have been keeping an eye out for years for somewhere to get custom laminations made and everything i found was ridiculously expensive. You've found the answer for me!

[oom_]

good work! also install some thermocouples to check the temperature of the stator winding while riding

[dwang]

Dude the amount of work and technical understanding you’ve got to get through all this on your own is IMPRESSIVE!!🎉🎉🎉

[puntabachata]

Thanks for walking us through. Great build!

[kezzatries]

I'm a motor rewinder of some 57 years experience on equipment from as small as dentists hand pieces (when they were electric) up to ships main drive armatures driven motors.
You did good, I'd employ you.

[afreestone]

Thank you for the fantastic video sharing your custom BLDC motor build for the bike! I've been looking to build a custom BLDC motor myself for a completely different application (small but powerful blower fan for a project I've been working on for years). Your mention of JY Stator suddenly had me glued to the rest of your video, as the stator was the very thing I've been having difficulty with! Incredible work on winding the stator by the way - it may have looked like mere minutes of work in your video (especially when you re-wound it!), but I know first hand that job can take HOURS! Keep up the awesome work - this is a truly rewarding hobby isn't it?

[charletonzimmerman]

Should use 'Slot Paper " & lacing for end turns also dip or pour varnish, of stator. US Navy rewinder, 2- years.

[ahaveland]

*Respect!* I tried to use a small 400kv bldc motor to drive my bike using emery paper on the outrunner bell pressed against the back tyre. It worked for a few meters and burnt out! Was incredibly hot to touch, but fortunately it looked like the magnets survived. It took a while - sourcing the right AWG of wire, 15T x 4 strands, 12 poies and 14 magnets, and finding a hydraulic press to release the core, took photos to record disassembly and managed to recreate winding layout and it worked first time!
Would have been much easier to buy a new one, but the satisfaction was priceless!

[pauljcampbell]

This was a very cool project. Regardless of the cost, the learning process was invaluable.

[murraymadness]

I've thought of many ways to make cheap motors, but unless your goal is just clicks for your channel (which is obviously the goal of many channels..) then you really need to think of where you can get cheap or almost free motors that are easy to modify. btw, I actually worked on converting a brushed dc motor into brushless.
I suggest you start looking for big ceiling fans, almost free. These are a great choice, but in my efforts I discovered many have the number of poles not divisible by three, so no 3 phase.
However, I've also learned that you don't have to build a 3-phase brushless motor! You can build a 4-phase one. A 3phase is just easier and uses less components, but that means NOTHING when you are doing it yourself for a one-off prototype.
The other option that is now become easy to find is direct drive washing machines, they have large diameter 3 phase motors in them that can be modified for lots of power.

[klave]

Fantastic work, well done. Loved the design process and innovative builds.

[mikkelr]

You know its a good day, when Austiwawa uploads! 👌

[enoh]

Brilliant! Very helpful to provide information around reasonably priced custom laminated cores.

[amogusenjoyer]

150$ is insane. It wouldn't even cover the cost of getting your cad file checked out in some places here... especially if you are looking for a one off thing. Just crazy!

[RobertBeck-ppru]

Excellent work and as you learned, we also learned. Good job!

[dansacco]

Very cool project. Interesting trick for removing enamel from the mag wire: Melt an aspirin tablet with your soldering iron and dip the wire in the puddle. It eats the enamel off the wires quickly. It also makes dangerous smoke so use a fume hood or other good ventilation.

[Ed_Stuckey]

Already a subscriber. As always, I 👍
I'm adding a comment because I'm told that helps too.