My Brushless Revo Bolt on conversion kit

Since I have a small machine shop (2 cnc mills and a cnc lathe), I set out to build a BOLT ON KIT that could be sold for less than 100 dollars in a retail setting, that would allow for a brushless drop in conversion (I know some of you will scoff at the novak setup but it was the cheapest and easiest conversion motor combo I could find).

Problem 1: Gearing (yea I know you all went through this too)
The stock gearing (like all nitro cars/trucks from my understanding) was metric to begin with, all the stock stuff is Mod 1 Metric teeth. I checked into my gearing and drive supplier catalog but couldn't find an easy way to adapt a metric gear to the Novak motor shaft (or any standard 540 motor shaft for that matter). I decided to do an 'end around', time to change the stock spur gear. After some messing around and searching, I found a suitable SAE pitch gear that Associated makes, and quite incidentally, it has three molded holes that were almost a perfect match to the 120 degree bolt pattern on the slipper!
So we keep the slipper (good thing IMHO), and now I had to just machine an adapter/spacer to get the gear mounted flat, (after 3 or for stripped gears I finally got one machined/sized correctly and now it is solid).

The second issue within the gearing adventure was that the gearing inside the gear box needed to be locked in a manner that would stand up to the torque and abuse of driving an overpowered electric vehicle. I tried the long bolt in the centrifigal clutch unit trick but the click clacking and not so instantaneous engagement pissed me off after a few runs. I also eventually stripped the screw off and then the steel stoppers molded into the gear.

Locking the reverse shifter was very simple, a nicely bent piano wire and a bolt took care of it. I used the Emaxx overall G/R on a Novak system as a guide and after lots of math, I settled on the second gear gear ratio and the associated gear and a 14-19 tooth pinion.

I then broke down and machined an ALU replacment hub for the second gear gearing (replacing the one way bearing hub completely and bolting into the gear). I completely ditched the first gear, and with the locking hub, the electronic braking and reverse work perfectly. Works like a Charm!

Problem 2: Motor mounting
So I started with a hybrid motor mount of carbon and aluminum, the carbon gave too much flex and I went to an all aluminum machined two piece motor mount which allows gear ratio and mesh adjustments. It bolts into the stock engine location as you can see in the pictures on my site.

I then designed some simple 2mm carbon fiber trays that bolt into stock bolt holes on the chassis for the battery and ESC, and its done.

Performance:

Holy cr*p! I ran a 14 cell (cheap 3000mah NiMHs) and then a 4s2p TP prolite setup it will wheelie on any surface even easing into the throttle, and is visibly faster than the nitro setup I had on my stock revo. I had removed all of the nitro workings including the throttle and shift servos, the rx pack, the plastics for them all, all the braking components, etc.

The verticle CG remains very much the same, so the handling of the truck (other than off the line grunt which was not even close in the nitro setup) is very much the same. I went to stiffer springs in the rear to better support the battery weight and keep the ride hieght higher for my personal bashing terrain and tastes but other than that the machine is pretty much stock.

(and now the best part)

Price: The conversion kit is 74.99 retail, and yes I will sell individual parts if you want them, see www.eaglesviewaerial.com/products.html for the kits. The only things you need to complete are BL motor, batteries of your choice, and a 14-19t pinion gear from Traxxas (from the Emaxx line).

Ok ok, pics, I can't post em because I took them in high quality format and don't have any of my image tools with me, check the website for detailed pics.

PLEASE NOTE THAT THE CARBON PORTION OF THE MOTOR MOUNT IN THE PICTURE IS NOW ALUMINUM....
(sorry, been out of town, need to shoot pics of the new mount piece).

I will post videos of it shortly, check my website for more details....
If you have questions or want parts machined, please let me know, I will try and do a run of hubs this weekend feel free to call me or IM/email with questions (ph:847-778-0874)