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I just got a digital micrometer! So I measured the taper on a test piece. I am taking 3 measurements at three different spots on each end and averaging them. I was at about 2.1 thousandths out over about 2.5 inches. And keep in mind this is after I did my rough leveling last night, so before it...

I used to ask myself what is wrong with my 7.75 mm drill bit. It was the largest drill before the reamer. The drill ran really funny and made weird noises. I thought it was a bad drill. But, the 7.75 mm drill cut like a dream after the 1/4” end mill got things cylindrical. So I think you were...

Thanks WB. I just ordered more steel bar stock and plan to make more iterations of the shaft until I have one that is viable, so this is a helpful option to try. Let me check my understanding Turn all outer diameter aspects of the extension shaft in one set up held in place between the chuck...

Thank you for the input and wisdom WB. I just tried this and it was very slick. I took some 10 mm aluminum stock and turned it down to pop-fit my extension shaft. I just tested the new shaft that I made using the procedure above and it was very clear to see the run-out issue that I had without...

I am still trying to reduce runout to 0.001" for a viable extension shaft on my motor. Keep in mind, I am just learning machine work with hobby grade equipment (challenged with set-up, rigidity, quality of tooling, speed limitations, limited torque, etc), but I am an engineer. I had moved away...

Hmmm my interference may be a bit too high as well. It is hard to measure the inner diameter of the hole in the extension shaft. But theoretically I am actually at about 17 microns of inference. Now that I have my technique down, I may try my 0.3140” reamer rather than the 0.3135” reamer that I...

I think I may have found some other potential contributors to the source of error on my extension shaft run out wonkiness after heat shrinking. I tried to remove the motor end cap, and it should have slipped right off. But, I was not able to remove it as it got stuck on a burr on the shaft...

Out of curiosity, what is the wall thickness of your extension shaft? Mine is about 3.8 mm. I am wondering if I have excessive force due to the wall thickness and what a lower viable limit may be.

regarding point 3 above, the bearings on my castle 1721 are tiny and their walls are super thin. I think that the OD of the bearing is smaller than diameter od the extension shaft. Hence I wonder if it would work to eliminate the original motor end cap in the spirit of shortening the shaft. In...

So, I cut off my last heat shrink shaft and took a peek inside the motor. does anyone know why there are bearings and brass bushings at each end? I thought it would be one or the other. There is also a sort of bent spring washer shim, which purpose I am guessing is to take care of end play. I...

Interesting. Thank you for the thinking and options. I am a novice machinist! I am only just getting my head around dimensions, much less concentricity, cylindrical, and how to measure and achieve them. I only recently bought blue and red loctite. I did not even know that there was a green...

Thank you for sharing. I am still trying to get my head around your design which is so simple yet robust in the right ways. So, how is the motor mounted to the turbo housing? I am guessing 4 machine screws with the compression limiters since 3D printed housing. Did you machine the original...

Thank you for the thoughtful reply. Yes, correct, all operations are made without removing from the lathe, or most recently between centers (which is repeatable concentric). Ahh, thank you for sharing that. Well that takes care of that hypothesis. So something else is going wrong. I will go...

Well, it has been a long time since I have posted. I have learned a lot about and advanced my capabilities on the lathe, made a lot of extension shafts. I have learned a lot about machining and measuring concentricity. I have systematically eliminated one problem at a time, but still don’t have...

Sorry about the frustration (time and money). Glad to see you will be running and learning again.

I have a Holley Terminator X stand alone ECU with the hand held display. I have been watching the hand held display and I seem to want boost when I get into the accelerator (somewhere north of 50% Throttle Position Sensor). Of course when that happens because the throttle is open, so the vacuum...

I have not had an e-turbo on my car yet. But here is what I know. No heat coming in from contact with exhaust No heat coming in from constant boost (only when spooked up) ABEC 5 (I believe but would have to check my notes) Bearing provided by e-turbo motor. I added a secondary bearing more...

I ordered and received another 0.3140” reamer from the same manufacturer. This one is just a few tenths over and has a tapered 45 bevel on the front of the reamer. Perhaps on the last one they missed the finishing and quality control steps. I guess i just had a bad reamer tool. So I will return...

WB, I wonder if there could be a problem with the configuration in the ESC regarding the number of poles, etc. I am now able to reproduce consistent sized holes with a nice wall finish albeit the same size of the shaft. I consistently get a measurement of the motor shaft of 0.3146” with my...

I do not put any timing in my electric motor (it spools up plenty fast). In fact, I have taken timing out for slowest ramp up setting and ramp it even slower than that with my arduino microcontroller . I am planning to take ignition timing out of my fuel injection algorithm as a function of boost.