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02-28-2010, 03:08 PM
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#1
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10 Second Club
Join Date: Feb 2008
Location: Eatontown
Posts: 1,647
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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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1999 C5 FRC: 12.7@114
2008 TBSS: 12.48@108
2017 Silverado 2500 do you even lift breh?
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02-28-2010, 03:18 PM
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#2
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Join Date: Dec 2004
Location: manchester, NJ
Posts: 1,775
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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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97 Firebird Formula - 383LT1
15 Subaru WRX - 2.0L-turbo
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02-28-2010, 03:19 PM
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#3
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Mongo the Meet Coordinator
Join Date: May 2008
Posts: 16,900
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Nice work, but Pro/E is bettaaaa. 
What size motor came stock? 540?
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Quote:
Originally Posted by KirkEvil
repo bigals turd gen and part it out to a loving home
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02-28-2010, 03:37 PM
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#4
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Join Date: Feb 2009
Location: bridgewater
Posts: 868
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that can looks too short to be 540
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Quote:
Originally Posted by BigAls87Z28
its an ongoing joke between the Geo Storm crew and the Sebring coupe team.
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bolt-ons and a bed n' breakfast
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02-28-2010, 03:40 PM
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#5
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10 Second Club
Join Date: Feb 2008
Location: Eatontown
Posts: 1,647
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Quote:
Originally Posted by LTs1ow
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.
__________________
1999 C5 FRC: 12.7@114
2008 TBSS: 12.48@108
2017 Silverado 2500 do you even lift breh?
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02-28-2010, 03:52 PM
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#6
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Join Date: Dec 2004
Location: manchester, NJ
Posts: 1,775
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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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97 Firebird Formula - 383LT1
15 Subaru WRX - 2.0L-turbo
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02-28-2010, 04:50 PM
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#7
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Join Date: Jul 2009
Location: barnegat nj
Posts: 1,340
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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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Quote:
Originally Posted by SRGN
I never pulled into the staging beams at the track and saw a dyno in the other lane.
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South Jersey Racecraft
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02-28-2010, 05:12 PM
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#8
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Join Date: Dec 2008
Location: NNJ
Posts: 1,489
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Awesome work! I wish my cutout opened in 2 seconds.
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1997 Camaro Z28 - 355 LT1, T56, CC503, LTs, ORY, Bald Eagle-back exhaust, !emissions, Lingenfelter CAI, EWP, !CAGS, BMR LCAs, UMI PHB, Koni Str.t/Koni SA, C5 Z06 front / LS1 F-body rear brake swap, factory hurst with short stick 
2014 2LT Cruze 2.0 Turbo Diesel
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02-28-2010, 05:21 PM
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#9
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10 Second Club
Join Date: Feb 2008
Location: Eatontown
Posts: 1,647
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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?
__________________
1999 C5 FRC: 12.7@114
2008 TBSS: 12.48@108
2017 Silverado 2500 do you even lift breh?
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02-28-2010, 05:25 PM
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#10
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Join Date: Jul 2009
Location: barnegat nj
Posts: 1,340
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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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Quote:
Originally Posted by SRGN
I never pulled into the staging beams at the track and saw a dyno in the other lane.
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South Jersey Racecraft
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02-28-2010, 06:00 PM
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#11
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Join Date: Dec 2008
Location: NNJ
Posts: 1,489
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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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1997 Camaro Z28 - 355 LT1, T56, CC503, LTs, ORY, Bald Eagle-back exhaust, !emissions, Lingenfelter CAI, EWP, !CAGS, BMR LCAs, UMI PHB, Koni Str.t/Koni SA, C5 Z06 front / LS1 F-body rear brake swap, factory hurst with short stick
2014 2LT Cruze 2.0 Turbo Diesel
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02-28-2010, 06:09 PM
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#12
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Mongo the Meet Coordinator
Join Date: May 2008
Posts: 16,900
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Can you retro fit mine like yours?
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Quote:
Originally Posted by KirkEvil
repo bigals turd gen and part it out to a loving home
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02-28-2010, 06:57 PM
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#13
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10 Second Club
Join Date: Feb 2008
Location: Eatontown
Posts: 1,647
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I had to cut the boot off, and it wouldnt fit over the new motor.
Quote:
Originally Posted by LTs1ow
Can you retro fit mine like yours?
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what?
__________________
1999 C5 FRC: 12.7@114
2008 TBSS: 12.48@108
2017 Silverado 2500 do you even lift breh?
Last edited by KirkEvil; 02-28-2010 at 06:57 PM.
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02-28-2010, 06:58 PM
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#14
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The Mayor / 2009 Member of the Year / Moderator
Join Date: Jan 2005
Location: Northwest
Posts: 8,864
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Quote:
Originally Posted by KirkEvil
what?
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My guess is Matt means he wants you to make his like yours.
__________________
1995 Z28 Convertible A4 13.78 @ 100 (CAI, high flow cat, catback, 160 thermo, hypertech, Strano springs, Koni yellows, sway bars, 3 pt. UMI SFC)
2018 Sea Doo GTX - 3 cylinders and das boooooost
Quote:
Originally Posted by BonzoHansen
Is English your 2nd language? Did you graduate high school? Your posts make my head hurt.
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 Team FARM 
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02-28-2010, 06:58 PM
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#15
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Mongo the Meet Coordinator
Join Date: May 2008
Posts: 16,900
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Quote:
Originally Posted by Anti_Rice_Guy
My guess is Matt means he wants you to make his like yours.
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__________________
Quote:
Originally Posted by KirkEvil
repo bigals turd gen and part it out to a loving home
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02-28-2010, 07:02 PM
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#16
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10 Second Club
Join Date: Feb 2008
Location: Eatontown
Posts: 1,647
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Quote:
Originally Posted by LTs1ow
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No.
__________________
1999 C5 FRC: 12.7@114
2008 TBSS: 12.48@108
2017 Silverado 2500 do you even lift breh?
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02-28-2010, 09:21 PM
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#17
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Join Date: Dec 2004
Location: manchester, NJ
Posts: 1,775
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ahaha i love it!
__________________
97 Firebird Formula - 383LT1
15 Subaru WRX - 2.0L-turbo
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02-28-2010, 10:17 PM
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#18
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Join Date: Jul 2004
Location: West Long Branch
Posts: 13,598
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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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2/20/2013: They Day the ****s Stopped
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02-28-2010, 11:22 PM
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#19
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Power Member/NJFBOA Bookie/Moderator
Join Date: Jun 2009
Location: North Jersey = Best Jersey.
Posts: 4,435
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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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03-01-2010, 07:30 AM
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#20
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Meet Coordinator
Join Date: Jan 2008
Location: brick/pt. pleasant beach
Posts: 19,341
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you da man kirk. ill come to you when mine doesn't work!
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03-01-2010, 02:15 PM
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#21
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10 Second Club
Join Date: Feb 2008
Location: Eatontown
Posts: 1,647
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Quote:
Originally Posted by Jersey Mike
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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If you run into problems where you cant make something yourself, QTP directed me here for replacement parts....
QTP Replacement Parts
__________________
1999 C5 FRC: 12.7@114
2008 TBSS: 12.48@108
2017 Silverado 2500 do you even lift breh?
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03-01-2010, 02:58 PM
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#22
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Power Member/NJFBOA Bookie/Moderator
Join Date: Jun 2009
Location: North Jersey = Best Jersey.
Posts: 4,435
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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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03-01-2010, 04:51 PM
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#23
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Join Date: Sep 2009
Location: Staten Island, NY
Posts: 206
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nice write up
which cut out do you have?
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383 Motor with 9:1, P1SC Procharger and much more
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