IMG_0766

iPhone 7 Plus
04/14/17 9:16:06 AM

MICR Chassis with flashing between 3\8 stainless shaft and the plastic base.

The flashing is causing a problem with the flywheel bushing not sitting on the chassis bearing flange. This raises up the flywheel and it can rub on the top center housing.

Need to fabricate some sort of tool to remove the flange without gouging the shaft or the chassis.

IMG_0765

iPhone 7 Plus
04/14/17 9:15:48 AM

IMG_0768

iPhone 7 Plus
04/14/17 9:16:35 AM

Here is a close up of the flashing. This small amount of material is preventing the bushing from sitting flush on the flange causing the flywheel to be slightly elevated and possibly contacting the plastic housing.

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iPhone 7 Plus
04/14/17 10:09:49 AM

Another view of the flashing.

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iPhone 7 Plus
04/14/17 10:17:33 AM

Another view of the flashing.

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iPhone 7 Plus
04/14/17 9:17:43 AM

Here you can see when the bushing is on the shaft the flange is not resting flat on the plastic surface of the housing.

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iPhone 7 Plus
04/14/17 10:17:48 AM

In this view you can also see that the shaft is leaning slightly right as it is not squarely insert molded into the chassis.

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iPhone 7 Plus
04/14/17 9:17:19 AM

When the flywheel is installed you can see it is sitting higher and you can also see the tilt of the shaft.

IMG_0793

In this image you can see that the shaft has not been insert molded in the center of the boss.

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iPhone 7 Plus
04/14/17 9:13:41 AM

I created this tool which uses the handle end of a standard exacto knife with the sharp end removed as a rotary scraper to remove the flashing.

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iPhone 7 Plus
04/14/17 9:13:53 AM

Wire frame view of tool design showing the internal hex for the drive shaft.

IMG_0764

iPhone 7 Plus
04/14/17 9:14:03 AM

A hex shape was printed in the drive end and a piece of 3/8 hex stock was pressed in so the tool can be turned with a power drill.  I have found that it’s only 3 or 4 turns required to remove the flashing and this is easily accomplished by hand. Works well with the drill also but it’s really easy to remove more material than necessary with the drill.

IMG_0777

iPhone 7 Plus
04/14/17 9:21:25 AM

Here is a shot of the actual 3d printed tool with the blades attached with 2-56 socket head cap screws and the 1.5” long, 3/8”hex drive pressed half way into the tool.

IMG_0778

iPhone 7 Plus
04/14/17 9:21:33 AM

3/8” Hex drive shaft pressed ¾” into the tool.

IMG_0785

iPhone 7 Plus
04/14/17 10:20:49 AM

In this photo you can see the tool resting on top of the flashing and can clearly see the gap between the cutting edge and the plastic flange that the bearing flange rests on.

You can also see that the gap on the left is greater than the gap on the right indicating a leaning shaft.

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iPhone 7 Plus
04/14/17 10:20:57 AM

In this photo you can see the tool resting on top of the flashing and can clearly see the gap between the cutting edge and the plastic flange that the bearing flange rests on.

IMG_0787

iPhone 7 Plus
04/14/17 10:21:14 AM

In this photo you can see the tool resting on top of the flashing and can clearly see the gap between the cutting edge and the plastic flange that the bearing flange rests on.

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iPhone 7 Plus
04/14/17 9:18:10 AM

Here is the tool mounted in the drill motor ready to remove the flashing.

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iPhone 7 Plus
04/14/17 10:22:57 AM

After 3 or 4 turns, the flashing has been removed and you can clearly see the cutting edge sitting flush on the plastic flange.

IMG_0789

iPhone 7 Plus
04/14/17 10:23:32 AM

After 3 or 4 turns, the flashing has been removed and you can clearly see the cutting edge sitting flush on the plastic flange.

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iPhone 7 Plus
04/14/17 10:24:21 AM

Here you can see that the flashing has been removed down flush to the chassis flange.

IMG_0790

iPhone 7 Plus
04/14/17 10:24:08 AM

This is another chassis where the tool was rotated by hand.

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iPhone 7 Plus
04/14/17 10:24:37 AM

In this shot you can see that the bearing flange is sitting flush with the chassis flange.

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iPhone 7 Plus
04/14/17 9:19:02 AM

In this shot you can see that the bearing flange is sitting flush with the chassis flange.

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iPhone 7 Plus
04/14/17 9:20:17 AM

Bearings installed in flywheel and sitting on the chassis.