Looking for a buggy project

[BrianG]

This might be done by the end of the weekend, so you'll have pics then. Right now, I'm using Legos to simulate the ESC mount for fitment purposes so it looks a little funny. :)

And yes, the Legos are mine. I find that I can easily make mockups of many things before building it for real.

[neweuser]

Sounds good Brian. Whenever you are ready. I bet the legos would fly with some lipo and esc with bl though!

[BrianG]

Originally Posted by neweuser

Sounds good Brian. Whenever you are ready. I bet the legos would fly with some lipo and esc with bl though!

Yeah, and fly apart with the first crash! :) And just to clarify; I just use Legos to simulate certain parts, mainly for fitment - not the whole buggy.

[neweuser]

Originally Posted by BrianG

Yeah, and fly apart with the first crash! :) And just to clarify; I just use Legos to simulate certain parts, mainly for fitment - not the whole buggy.

I figured that mcuh, but I know how much you like to take things apart and put them back together! LOL:005:

[glassdoctor]

Now we know why it took so long to get the buggy done.. you spend all your time playing with legos, lol.

I use cardboard to mock up stuff sometimes. Anyone want a pretend 4s 6000mah pack? It kinda looks like the real thing... hee hee

LOL i think im going to pass on the carboard lipos.. altho it would be nice and light LOL

amd yay lol i want to see pics with everything in it

[BrianG]

Originally Posted by glassdoctor

Now we know why it took so long to get the buggy done.. you spend all your time playing with legos, lol.

Awww man! You caught me! :dft001: We all have to have our toys! ;)

I've used cardboard too, but Legos are easier and faster to make stuff. Plus, you can make small adjustments without having to build from scratch. I actually have my Lego bins near my workshop area. :)

Lol, E-MAXX Rock's. Patience! I did make some headway tonight though. Made the receiver mount, replaced the gasket in the diff, made and thermal epoxied the heatsink for the Quark, figured out how I'm gonna have the ESC mount set up, and figured out the wire routing. Not bad for one night.

[neweuser]

Originally Posted by BrianG

Awww man! You caught me! :dft001: We all have to have our toys! ;)

I've used cardboard too, but Legos are easier and faster to make stuff. Plus, you can make small adjustments without having to build from scratch. I actually have my Lego bins near my workshop area. :)

Lol, E-MAXX Rock's. Patience! I did make some headway tonight though. Made the receiver mount, replaced the gasket in the diff, made and thermal epoxied the heatsink for the Quark, figured out how I'm gonna have the ESC mount set up, and figured out the wire routing. Not bad for one night.

That is pretty good progress Brian. So you thermal epoxied the heat right to the quark? Or did you put it in the case of the quark?
Can't wait to see the completed project!

[BrianG]

I only epoxied heatsinks to the external case. I'll wait until the warranty runs out before I do any improvements to the ESC internals.

I can't wait to see the completed project as well! :)

[neweuser]

Originally Posted by BrianG

I only epoxied heatsinks to the external case. I'll wait until the warranty runs out before I do any improvements to the ESC internals.

I can't wait to see the completed project as well! :)

Brian, if I may ask. I thermal epoxied my fan mount wings to the bottom of my rear custom heat sink. Now, when do this, the epoxy did not seem to be AS strong where you would not be able to remove the object after it dried. Stronger than the paste yes, and yes it dried hard, but my question is..."how hard would it be to remove the esc from the epoxy?"
The reason I ask is because I would love to epoxy my Quark to my rear heatsink. But if it's harder than hell to remove in case of damage, then I may not want to. But it seems that it may not be. If I could epoxy with some effort to remove it, then I would definately do this instead of zipties...

[BrianG]

Well, the fan wings may not have as much surface area to grab on to. Also, thermal epoxy is meant for closely mated surfaces. Remember; any thermal paste/epoxy is meant only to fill in the microscopic imperfections in the mating surfaces. The Epoxy just has the added feature of being a bonding agent.

From all reports, thermal epoxy is permanent if the surfaces were clean and there was enough surface area. Sometimes, you can seperate two epoxied items by placing them in the freezer for 1-2 hours and then gently prying them apart. It's not guaranteed though. And I would NOT try this on any heatsink that is mounted directly to the FETs - the FET pins will most likely break before the epoxy does. But you could try this on a sink attached to the external case with minimal fuss as long as you don't apply too much prying force.

If you post a pic of your present mount, maybe I could offer an alternative mounting suggestion.

[neweuser]

here is a shot of the bottom

here is a shot of the top

here is a shot of the side, but it's a bad shot! lol

this might be too far away to see...but it might be clearer

[BrianG]

OK, I see. First, I would use screws to hold down the fan mounts. Just countersink the screws from the top.

As to holding the ESC down, how about a clamp? A piece of 1/16" thick 6061 Al, about 3/4" wide that goes across the top of the ESC and then screwed down on each side? Or maybe make one side hook under the plate and then screw down only one side? Then you could use thermal paste instead of adhesive. It looks like the mounting plate is very close to being the exact dimensions of the ESC (on 3 sides anyway).

Nice truck BTW. :)

[BrianG]

At last! It's done!

Wire routing was a challenge with the Quark, but I think it'll work just fine.

Pics:







And finally, a pic of the balancer Y adaptor. I made the leads quite long so the batts can sit in my Liposack without having the balancer crammed up against the sack.



The Quark is thermal-epoxied to a 1/16" thick sheet of 6061 Aluminum with a couple of these heatsinks epoxied to the sheet. I wasn't sure if 1/16" thick Al would transfer heat fast enough, but temps between the sinks and the ESC case are very close. And the sheet allowed me to secure it to the ESC mount without using zipties. Yay!

[jnev]

That thing looks aboslutely awesome. The wiring may have been a challenge, but it looks very clean and like you bought the whole buggy like this.

Have goten a chance to try it yet? Any estimates on run time and/or speed?