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Old 02-28-2010, 03:08 PM   #1
KirkEvil
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Ultimate Electric Cutout Disection

My electric cutout seized, and was stuck open for a week . Needless to say I was annoyed so I took everything apart.



The rubber boot that was supposed to weather proof the motor did a pretty good job of collecting water. The inside of the wimpy motor supplied with the cutout grenaded . After opening it up, I was surprised it had no signs of failure before seizing up.

Anyway, I decided to upgrade to a bigger motor and show some pics of the inside of the gear box...

The Gear Box...


The inside...


Disassembled...


Mini gear carnage...


I pulled the gear off the old motor and pressed it onto the new one, but the shaft was longer so it needed to be shimmed...

Old vs new motor...


New motor mounted...


Shows new motor with gear engagement...


Going back together, blue makes everything better...


I didnt feel like getting raped by QTP for a controller, so I went with the radioshack special; DPDT switch (on the right)



Since wiring cutouts can be confusing, I made a sweet diagram that may help some people out....



The new motor opens/closes the cutout valve in about 2 seconds as opposed to the stock motor which took about 6 seconds.

I also picked up a sound measuring device from the engineering building : I run pacesetter LT's, ORY, and a hooker aerochamber. Measuring device held at passenger door, about 3 ft. from cutout.

Surrounding Noise: 55 dB
Idle cutout closed: 64 dB
Idle Cutout open: 96 dB

Hope somebody finds this stuff interesting.
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Old 02-28-2010, 03:18 PM   #2
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damn engineers making everything super complicated. I'm impressed though. Nice work man cant wait to hear that cutout open with the cam!! Do you still have that sound measuring tool. I would like to compare it to my car when i can get it out on the road.
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Old 02-28-2010, 03:19 PM   #3
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Nice work, but Pro/E is bettaaaa.

What size motor came stock? 540?
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Old 02-28-2010, 03:37 PM   #4
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that can looks too short to be 540
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Old 02-28-2010, 03:40 PM   #5
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Quote:
Originally Posted by LTs1ow View Post
Nice work, but Pro/E is bettaaaa.

What size motor came stock? 540?
Solid Works beats all, but Im biased towards AutoCAD. Not sure of motor size, all the specs were torn off it when I pulled the rubber boots. I think its smaller than a 540 though.

Brandon, I can borrow the sound metering device for next weekend's cam swap.
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Old 02-28-2010, 03:52 PM   #6
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yea my car wont be there. i might not be able to make it next weekend... i could have this weekend if Adam didn't bail, but next weekend is my b-day i may be going out with a couple people. so don't worry about it.
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Old 02-28-2010, 04:50 PM   #7
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nice job kirk, glad to see your not shy in getting you hands dirty and fixing stuff yourself.
& nice job with diagram. i'll be sure to use that on mine....twice (2 cutouts)
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Old 02-28-2010, 05:12 PM   #8
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Awesome work! I wish my cutout opened in 2 seconds.
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Old 02-28-2010, 05:21 PM   #9
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I was just happy I had a motor that was relatively close to the stock one, the faster open/close was a bonus.

I just have to come up with a better way to seal the assembly now. I was thinking of masking off the motor and surrounding it with silicon. Anyone have suggestions?
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Old 02-28-2010, 05:25 PM   #10
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dip it in wax or if you access to the wax type sealer that i used to waterproof circuit boards in electrical class.hot candle wax or that plastic dip thats used to make new handles on pliers.
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Old 02-28-2010, 06:00 PM   #11
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What happened to the rubber boot? How long was it under there like that? I def don't want mine lookin' like that, maybe I'll get some silicon in there...
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Old 02-28-2010, 06:09 PM   #12
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Can you retro fit mine like yours?
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repo bigals turd gen and part it out to a loving home
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Old 02-28-2010, 06:57 PM   #13
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I had to cut the boot off, and it wouldnt fit over the new motor.

Quote:
Originally Posted by LTs1ow View Post
Can you retro fit mine like yours?
what?
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Last edited by KirkEvil; 02-28-2010 at 06:57 PM.
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Old 02-28-2010, 06:58 PM   #14
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Quote:
Originally Posted by KirkEvil View Post
what?
My guess is Matt means he wants you to make his like yours.
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Old 02-28-2010, 06:58 PM   #15
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Quote:
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My guess is Matt means he wants you to make his like yours.
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repo bigals turd gen and part it out to a loving home
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Old 02-28-2010, 07:02 PM   #16
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Quote:
Originally Posted by LTs1ow View Post
No.
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Old 02-28-2010, 09:21 PM   #17
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ahaha i love it!
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Old 02-28-2010, 10:17 PM   #18
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Holy Nerd!!
Nice work, but would have went with Pro/E or Solidworks with the switch. AutoCad is just rough looking.
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Old 02-28-2010, 11:22 PM   #19
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Funny. My cutout just decided that it didn't feel like closing more than a 1/3 of the way, effective Friday night.
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Old 03-01-2010, 07:30 AM   #20
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you da man kirk. ill come to you when mine doesn't work!
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Old 03-01-2010, 02:15 PM   #21
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Funny. My cutout just decided that it didn't feel like closing more than a 1/3 of the way, effective Friday night.
If you run into problems where you cant make something yourself, QTP directed me here for replacement parts....

QTP Replacement Parts
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Old 03-01-2010, 02:58 PM   #22
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Thanks for the link, Kirk! The sun is quickly melting the snow away, so I'll probably get under there tomorrow to see what exactly is happening.
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Old 03-01-2010, 04:51 PM   #23
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nice write up

which cut out do you have?
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