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REVIEW
CLOSEUP
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Nitro powered
Hyper 7 PBS
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Goal
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Convert a 1/8 scale nitro powered buggy to electric
brushless
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When
working with off-road electric applications, brushed motors do
not have enough torque to give it the speed and the power that
people want. This is why we chose a high quality burshless ESC
and Motor for our application. Using a brushless motor you only
need one instead of the two motors that a brushed setup would
require. One motor will deliver enough power to give us the low
end torque and top end speed we expect from a nitro buggy.
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To
show that electric can be just as fast or powerful as a good nitro
powered RC. In our project we took a nitro powered 1/8 scale buggy
and converted to electric.

Nitro
powered Hyper 7 1/8 scale buggy before the from nitro to electric
conversion.
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Picture
of the shop - Lathe and CNC Mill for making custom RC parts.
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1/8
scale buggies are very strong, durable, fast and can not be purchased
as an electric RC on the retail market. Therefore some of our
parts we had to either modify or make ourselves.
Needed
items for conversion:
- Brushless
ESC
- Brushless
Motor
- Motor
mount
- Steering
servo tray and servo
- Pinion
for electric motor
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| Since
1/8 scale buggies only come in nitro form, we need to make a custom
motor plate to mount an electric motor. Start off by removing
any parts that had to deal with the nitro engine and disk brakes.
The throttle brake servo is no longer needed anymore. Electric
RC's use the motor for brakes.
Next
step will be to measure the mounting holes on the center diff.
We will design and connect a motor plate onto the center differential
to allow us to mount an electric motor. We will be doing all
our measurements in millimeters (mm). We want 100% accuracy
so we will design the motor plate on the computer and cut it
using a CNC-Mill.
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Hyper
7 buggy with all unnecessary parts removed.. Leaving only what
we need.
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Shows
measurements and design of the new motor plate to be made on
our CNC mill. This will allow a single electric motor to be
mounted on our Hyper 7 PBS.
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Motor
plate being cut out from 6061 aircraft quality aluminum on our
CNC-Mill in our work shop.
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CNC'ed
motor plate that will be used on our brushless conversion. After
it was cut out we trimmed the thickness of the plate from 6mm
to 5mm allowing enough room for our pinion gear to sit properly
on out motor shaft. |
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| For
the steering servo we will just modify the stock servo tray. We
will cut away the part that holds the brake servo and keep the
part that holds the steering servo only. |
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Draw
a line where you want to cut away the steering servo from the
brake servo.
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Cut
the servo tray where you drew the line.
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The
servo tray should look similar to this picture once it has been
cut. Again this could have been done with a dremel tool, but
would not have been as clean or straight if we did that.
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Once
you have the motor plate and servo tray ready, mount it on the
buggy to make sure everything fits. If things do not fit correctly,
you will have to remake the parts until you get them correct.
It is very important to have the bottom of the pressed up against
the bottom of the chassis of the buggy. This will prevent any
damage to the center differential, pinion gears or the motor shaft
from the torque of the motor. |
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mount and fit everything onto the buggy and start trying to figure
out how you want to setup your batteries. I plan on running with
12 cells and will try to balance them by placing 6 cells on either
side of the buggy. Also take not that I used a cheap brushed motor
when I am sizing everything up to make sure everything will fit.
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though we designed a motor plate from scratch and CNC'ed it. This
can also be done by modifying an EMaxx motor plate and using it
instead. The following will show how to modify an EMaxx motor
plate instead of making on from scratch. Using an EMaxx motor
plate is good for those who want to run 2 motors on their converted
buggy. This is also good for those who can not afford a high end
brushless system. One could get two EMaxx motors and a Novak ESC
and run a dual brushed motor setup if they would prefer to do
so. |
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First
get yourself a motor plate from an EMaxx.
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Hold
the center differential support up to the motor plate for making
measurements for cutting.
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Cut
motor plate where you marked and drill the proper screws for
mounting. Even though we used a CNC Mill for cutting, when modifying
an existing motor plate one could use a dremel tool or something
similar to cut for a tight fit.
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Size
everything up and mount it to make sure it fits. It is good
to try to fit your motor and pinion as well. When we are sizing
things up we use a cheap brushed motor and pinion as shown in
the picture.
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| Once
everything has been fitted and installed. Now is the time to make
changes if necessary. We started off by making the plate from
cheap aluminum and then after test fitting we resized a couple
of areas and then remade the plate from 5mm thick 6061 air craft
quality aluminum.
Many
things to decide when doing a nitro to electric conversion like
this. Need to decide what motor, ESC, gearing, batteries, how
to mount the batteries, where to mount the ESC and receiver,
where to put the antenna and many other items alike.
Well
first person I thought of was Jamie at Starluck
RC. Asked him what motor and ESC he recommended. Jamie recommend
the BK Warrior 9918 brushless controller with a Feigao 10L brushless
motor. The metal differential gears on 1/8 scale buggies are
a Mod-1 pitch. Most manufactures will tell you that they are
32 pitch gears on the metal differentials, if you try to do
this with 32 pitch gears they will strip very quickly and easily.
When we asked Jamie about what gears to use, he recommended
a 16 tooth hardened steel Mod-1 pitch pinion gear with a 5mm
bore to fit onto our Feigao 10L motor.
For
batteries, we chose to run 12 matched GP3300's provided by Model
Electronics, Corp. To balance the buggy equally we mounted
6 cells on each side of the chassis. Long Velcro straps were
used to hold the batteries onto the buggy. I do not care for
soldering cells, so we used Model Electronics patented (SPT)
Solder-less Power Tubes. This way we can re-assemble the cells
into different configurations without having to worry about
un-soldering or re-soldering the cells back together. Later
we will do a setup with 16 or 18 cells and this product allows
us to do that more easily. For now we will just run 12 cells.
Technical
Note:
One of the most important things when running a high end brushless
system is your batteries. Using everyday sport packs will cause
loads of cogging and hesitation within the motor and ESC. It
is very important that you use very high end cells. Also make
sure you are using Deans connectors and not the plastic Tamiya
connectors. The Tamiya connectors are very low quality connectors
and will cause problems or can even damage a high end brushless
ESC or Motor. If you are unsure of the quality batteries you
have then replace them. Do not take chances. Brushless motors
and ESC's are not cheap, make sure your batteries are not either.
This is why we asked Pete at
Model Electronics, Corp to personally match and zap our
cells for us.
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Everything
mounted and ready-to- run. Just need to charge the batteries,
put the lid on and go.
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Need
to make sure everything sits low enough to allow room for the
buggy body.
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Hardened
steel 16 tooth Mod-1 pitch pinion. Making sure you have a proper
gear mesh is important.
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We
used Velcro straps for mounting the batteries. Just cut slits
using a dremel or similar tool to allow the Velcro to be ran
though the rock guards.
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Test
fit the body - make sure everything fits under the lid and nothing
is rubbing anywhere.
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| On
the first test run, this thing was amazing. Was zipping down the
street in front of my house a lot faster than when it was powered
by nitro. The run times depend on how hard you run it. The harder
it is ran, the shorter the runtimes. Runtimes averaged 8 - 15
minutes. Performance and runtimes will vary depending on what
ESC, motor or batteries being used.
We
took this new electric powered buggy to the stray in Harrogate,
England. There we bashed it around pretty hard and did manage
to get a short video. The video was cut
short because the bitter cold made the plastic parts very brittle.
We ended up breaking the wing mount and rear differential case
on the brushless powered Hyper 7. After owning this buggy
for almost 2 years, finally broke my first part.
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Final
Review and thoughts:
On the first run of this newly created masterpiece, all I could
say was WWWOOOWWW!!!! This thing has never accelerated this fast
as when it had the Hyper 21 8 port nitro powered engine. Not only
did it make marks through the grass, but it left deep ruts. I
just wish I did this sooner. Even the top end speed was just unbelievable.
The power delivered from the brushless motor was more than enough
for any off-road RC vehicle 1/10 or 1/8 scale. All this without
the mess or the hassle for tuning of the nitro engine.
Those
who are reading this that want unbelievable power and speed
out of their 1/8 scale buggy, then this is a must. Personally
I love making RC's go fast. That goes for the fastest acceleration
and fast on the top end too. This is definitely a lot faster
on both than when it had the 8 port Hyper 21 nitro powered engine.
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Video:
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Click
here to play video.
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