Anyone tried repairing a broken motor shaft/armeture

[TMXONR]

I have a Castle Creations 4600 motor that the pinion shaft of the armature broke off. I talked to castle and it is still under warranty. I just don't want to give them a cc number for collateral. I would send the motor first, but I need it done quick and not 4 weeks link their site says, so I will just buy a new motor if I screw this one up.

Anyway on to my question. I have access to a full shop at school to work with this. Has anyone tried TIG welding a broken shaft back on. I figure that I can tig it back on and then stick the armature in the lathe and true the shaft back up with a bigger radius, instead of the flat edge where the shaft broke. The break looks to have started where the edge of the flat spot on the shaft ended and the taper begins.

Does anyone see any problems with doing this would it hurt the magnet.

[binaryterror]

Well heat from any welding + magnets = no more magnet. You could try heat sinking the magnet all you want, but any loss of magnet power will make the motor terribly underpowered and slow.

I don't understand your want to do this.

Doing it, voids the warranty instantly. So now Castle won't even repair it if you mess up, so you are out $.

Just give them a CC number and get a new motor fast...or buy a new one and send in this broken one. Either way in this case you don't get hosed.

[syber70]

Buy the new motor, send that one back for repair professionaly.

when they send it back, you have two motors.... nice to have a spare.

But one with a different turn to it, and you'll be able to play with different configurations.

[EddieO]

The magnets could probably take the heat of a repair, but you would have to be quick.....the problem is, I doubt you will ever get it straight enough to stop the rotor from exploding, even at low speeds. It will be terribly unbalanced, which will not only end up going boom, but you will lose power and efficiency.

And worst yet, any warranty you may have will be gone....

I suggest what the other posters do, buy a new motor to use and send this one back in for repair........when it comes back, you got a spare you can keep or sell.

I gotta ask though, how on earth did you break an armature shaft?

Later EddieO

[TMXONR]

I figured the magnet or balance would end up being a problem. I guess I will run a new motor and send this one in.

Originally Posted by EddieO

I gotta ask though, how on earth did you break an armature shaft?

I am not sure how it broke. I was running it at the Monster Jam here last Saturday. I hit the ramp, landed and when I tried to turn my buggy (B44) around, it wouldn't go. I checked it after we were done and I saw the pinion and shaft laying in the center of the chassis. I can't think of how it could have broken. I wasn't on the throttle when it landed, there was no signs of debris in the pinion or spur gear, and it wasn't a hard enough landing for the motor to put that much strain to break the shaft. There are some scratches on the can from running it on the track, but no hard impacts.

[Lonewolf]

If you are not running a slipper that might explain it. When jumping its a good idea to attempt to keep the wheels spinning the same speed, letting off of the throttle will slow the wheels and when the vehicle lands its like haveing instant breaks, the tires grab and snap.... I blew alot of diffs on my nitro USA 1 till I learned about keeping the tires spinning and close to the same speed. minor adjustments to speed only enough to keep vehicle from flipping in the air. More throttle causes backflip less throttle causes nose dive. Stopped tires= broken parts in drivetrain.

[TMXONR]

I was off the throttle but the wheels were rolling. I have the slipper set up on my buggy. Since I race it, I make sure it is set up pretty well for long lasting good performance. I actually lasted most of last season on my origional diff gears, and never stripped a spur gear. The other guys were always stripping gears. I know how to drive.

This is on my B44, so its not a basher that I beat the crap out of. The only reason I had it at Monster Jam was so I could run for the entire time we were supposed to be out there running with out having to refuel my T-Maxx.

[theslowguy]

Originally Posted by TMXONR

I have a Castle Creations 4600 motor that the pinion shaft of the armature broke off. I talked to castle and it is still under warranty. I just don't want to give them a cc number for collateral. I would send the motor first, but I need it done quick and not 4 weeks link their site says, so I will just buy a new motor if I screw this one up.

Anyway on to my question. I have access to a full shop at school to work with this. Has anyone tried TIG welding a broken shaft back on. I figure that I can tig it back on and then stick the armature in the lathe and true the shaft back up with a bigger radius, instead of the flat edge where the shaft broke. The break looks to have started where the edge of the flat spot on the shaft ended and the taper begins.

Does anyone see any problems with doing this would it hurt the magnet.

Why dont you just buy a new rotor? I know you can buy new ones for all the novaks and stuff.

[TMXONR]

Originally Posted by theslowguy

Why dont you just buy a new rotor? I know you can buy new ones for all the novaks and stuff.

Castle Creations doesn't sell motor parts.

[theslowguy]

Hmmm. I didnt know that. I wonder how compatible the rotors would be. I know a lot of the different brands are either designed or designed and built for various companies by NEU motor company. Maybe measure the broken rotor w/ a dial caliper and look up some of the vatious replacement rotor specs to see if any match up. Just throwing out ideas.

[TMXONR]

I can't take this one appart anymore, since I am gonna send it in now. I have had a Castle motor appart before though, and they look different than the Novak rotors I have seen. I haven't compared on with any other brand though.

[NovakTwo]

Our rotors are not really compatible with other sensored motors. The slotless/sensorless motors use a completely different rotor design. Many motors are not designed to be re buildable, such as the Chinese-built SL motors

Novak's design philosophy is to offer re-buildable products and make sure that the repair/upgrade parts are always available for the user. The more small repairs that can be handled by the user, the longer the product will be usable and the fewer trips back to the factory for service.

A broken rotor can not be repaired, as posters above have noted.

[JohnRobHolmes]

There could have been a void or inconsistency in the steel. I vote warrenty and just buy a new one in the mean time, you are out the same cash and you won't mess it up by welding the shaft back on.