Motor Mount - Welded Steel 2.0

While developing new welding skills this week, work was continued on the new design for a steel mounting clamp for the Warp 11.  Each effort demonstrated new challenges for work set up and metal preparation.  In the future, all of the surfaces that will be welded will be light sanded to remove mill scale before the pieces are tack welded together for assembly.  It is much harder to remove the scale after the pieces have been partially assembled.  Another significant detail, learned by trial an error, is the need to use multiple vice grips to hold the assembly in the correct planes and orientation prior to tack welding.

 

Picture DSC00491 showing the beveled edges of the center steel prior to tack welding the angle iron pieces to each side.

                          Picture DSC00497 which demonstrates the setup prior to welding. 

The initial half of the curved steel clamp was carefully measured, the angle iron "flanges" positioned with vice grips, the pieces tack welded together, and finally all of the seams completely welded and ground down for a smoother surface finish.  Welding of the complimentary steel clamp required more care to ensure that both sets of flanges were both in alignment with each other and in the same plane.  Picture DSC00497 above demonstrates the method used.  Initially the work was placed in the bench vice to hold both (right side of the picture) angle iron pieces firmly and in parallel alignment.  An aluminum flat stock was then vice gripped to the outer face of the previously welded angle iron (on the left side), and finally the remaining angle iron (front left) was held (top to bottom) with another vice grip after it was positioned flush with the aluminum plate.  Tack welding locked in the required position, and then complete seam welding finished the job.

 

Picture DSC0495 with Peter from Boy Scouts Troop 95 demonstrating the proper method for welding the steel angle iron.

 

 

Picture DSC00505 showing the side view of the original aluminum top design with the steel bottom support ring.  Note that this design will allow for the bottom extraction of the Warp 11 motor without removal of the upper aluminum clam shell and the side mounting adapters.  This capability may be of value if the space above the aluminum clam shell is occupied by a controller or with batteries that may be difficult to remove and replace.

 

 

 

 

Picture DSC00508 shows an oblique view of the mounting flanges prior to welding the BMW OEM sectioned piece to the outer aluminum flange.  Two plastic spring clamps were used to hold each of  the aluminum pieces together for the photograph.

 

 

 

 

Picture DSC00512 showing one of the new steel rings with the welded angle iron. This configuration could be used when the engine mounts are higher than the equator of the rings. 

 

 

 

 

Picture DSC00514 showing one of the new steel rings with the welded angle iron. This configuration could be used when the engine mounts are lower than the equator of the rings. 

 

 

 

Picture DSC00502 with both steel rings in place.  Prior to attaching rubber gaskets onto each inner curved surface, any excess welding buildup will be ground smooth.  The camera angle does not show it properly, but both left and right mounting faces are actually parallel to each other and both are perpendicular to the floor. 

 

 

Picture DSC00504 showing an oblique view of the mounting faces of the combined top and bottom steel rings.  The required location for the mounting bolt holes will be determined after the assembly is trial fitted into the motor compartment.