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Broke OG Sherm axle, options besides buying another motor?


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I was told at ewheels that it's a pretty special process of replacing the axle, that it needs to be "pressed" in and I didn't consider getting the motor wires through the axle. Can only LK do it, and is it as expensive as buying another motor? Worst case if getting it in is not as hard as it seems I can get the ring terminals through the axle hole which I assume is how they did it on the assembly line? Thanks for any help

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There is Russian specialist firm who made a replacement CNC axle for the OG Sherman, ISTR. It’s mentioned in another earlier thread. Off the top of my head I can’t remember the name of the firm but they exist, or certainly did. If you search back through the Veteran thread here hopefully you’ll be able to find it. I’m unfamiliar with the process of actually replacing the axle though, but it must indeed be possible to have this done in a shop with a hydraulic press.

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2 hours ago, Freeforester said:

There is Russian specialist firm who made a replacement CNC axle for the OG Sherman, ISTR. It’s mentioned in another earlier thread. Off the top of my head I can’t remember the name of the firm but they exist, or certainly did. If you search back through the Veteran thread here hopefully you’ll be able to find it. I’m unfamiliar with the process of actually replacing the axle though, but it must indeed be possible to have this done in a shop with a hydraulic press.

Oh I'm not worried about getting another axle as I mentioned ewheels has it (and I'm kind of impatient:lol:) only the process in getting it in, and I see that I'd need a hydraulic press. How should the wires get in too? I think that's what I was most worried about. Thanks

Edited by destruver
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16 hours ago, Freeforester said:

There is Russian specialist firm who made a replacement CNC axle for the OG Sherman, ISTR. It’s mentioned in another earlier thread. Off the top of my head I can’t remember the name of the firm but they exist, or certainly did. If you search back through the Veteran thread here hopefully you’ll be able to find it. I’m unfamiliar with the process of actually replacing the axle though, but it must indeed be possible to have this done in a shop with a hydraulic press.

Also, will the shop be able to remove the old axle? I'm wondering how this is done without damaging the motor. Trying to not have to shell out 400 more for another motor than the price I was given for the axle

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10 hours ago, destruver said:

Trying to not have to shell out 400 more for another motor than the price I was given for the axle

Removing the old axle and inserting, welding and rewiring the new one in is a job that can quite easily cost more than a new motor whether you outsource the job or calculate any kind of worth to your own time. Personally I don’t see fixing an axle to be worth it unless one is curious and dedicated enough about whether/how it can be done. But to save money? Nah.

Edited by mrelwood
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5 hours ago, alcatraz said:

Check for axle replacement videos on begode wheels. They shold be pretty similar.

Thanks. For now I contacted LK and am waiting for a response on how to do this the proper way. Now that I know the heavy duty process involving the axle, I'm just worried about the wires.  I hope they don't think I'm trying to dabble in their industrial secrets to copy them 🤣

 

3 hours ago, mrelwood said:

Removing the old axle and inserting, welding and rewiring the new one in is a job that can quite easily cost more than a new motor whether you outsource the job or calculate any kind of worth to your own time. Personally I don’t see fixing an axle to be worth it unless one is curious and dedicated enough about whether/how it can be done. But to save money? Nah.

I do agree with inserting when it comes to labor at the shop, but I don't think it has to be "welded" and "rewired," as I learned it's only a process of it being pressed in, I might have messed phrasing before but I was originally concerned about getting the motor wires in the axle, it does seem like those wire terminals can fit through there, not sure if that's before or after pressing though.

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Edited by destruver
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Replacing the metal is just half the battle... 

1 hour ago, destruver said:

it does seem like those wire terminals can fit through there

No; the terminals won't fit. You can only pass the bare cable through the axle hole; the board connectors must be installed after. 

You'll either have to choose to re-use your old cable (which is worn and has dirty solderjoints now, which you'll need to disconnect and then resolder); or source and install a new cable, which will be a fussy challenge to solder and re-secure the connections inside the motor for the phase wires and hall sensors.

Remember that if any of these connections fail while riding, you crash. 

It's new motor time.
Perhaps post a "Want To Buy" in our classifieds or on facebook, looking for a good used Sherman motor stator with cable, like from a rim damage accident.
 

Edited by RagingGrandpa
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3 hours ago, destruver said:

I don't think it has to be "welded" and "rewired,"

I’m not 100% sure which parts are welded together, and if there are parts around the axle that the welding is done to instead. But the stators have been welded to some part of the axle in all EUCs motors I’ve seen first hand or photos of. This doesn’t negate the use of a press, the tolerances are very tight.

By rewiring I meant desoldering the 8 cables, pulling them out through the axle, prying them all back in through the new axle without damaging them, and finally soldering them back into place. These are also steps that can’t be avoided. And like @RagingGrandpa reminded, a bad soldering job, torn insulation etc. on any of these wires can cause an instant crash. So you better trust your soldering skills if you plan to DIY.

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12 hours ago, RagingGrandpa said:

Replacing the metal is just half the battle... 

No; the terminals won't fit. You can only pass the bare cable through the axle hole; the board connectors must be installed after. 

You'll either have to choose to re-use your old cable (which is worn and has dirty solderjoints now, which you'll need to disconnect and then resolder); or source and install a new cable, which will be a fussy challenge to solder and re-secure the connections inside the motor for the phase wires and hall sensors.

Remember that if any of these connections fail while riding, you crash. 

It's new motor time.
Perhaps post a "Want To Buy" in our classifieds or on facebook, looking for a good used Sherman motor stator with cable, like from a rim damage accident.
 

Hmm, they didn't seem bigger than the axle hole, maybe it's through the rest of the axle, it wouldn't fit? Guess I got that wrong, but I can't just remove the terminals, then resolder/crimp? (unless they're on there tight, then worst case I'd mess the wire up pretty good.) I'm not seeing how I'd have to mess with any motor internals (unless I had to replace the wires). Def not touching no halls tho, but willing to get my claws a bit dirty before I pull the trigger for anything  :D

Edited by destruver
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7 hours ago, Freeforester said:

Let us know how it goes!

Thanks. I understand you said you're unfamiliar with the full process but it definitely has to be pressed in so I'll see what I can do with the terminals.

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