I spent a little time fucking around (pun intended) with the new machine. I got a 5/16″ ID 32 tooth timing pulley with the minimal number of teeth. It is the perfect match to the rest of the machine. Speed, power, acceleration are more than i could hope for in a small machine. This machine will satisfy all but those who need a telephone pole rammed up their holes at 60 MPH. There is no slipping because of the timing belt and the torque is amazing with the little (physically, not power) motor. I am also amazed at how well the little switching power supply works with the rest of the components. This greatly simplifies the design and reduces the cost.
I don’t know why it works so well with these minimal components, just some sort of lucky match, maybe.
I still need to do some real testing to make sure it performs as well in the real world as it seems to in the virtual. Once i do some hole fucking testing i will give it the good fucking seal of approval. Once this is granted, there is no reason to not build one of these machines. Low cost, low weight, high power, speed and acceleration. No slipping. No dithering.
As soon as i give it the real test, i will start working on a parts list and some construction details. I will probably just take some pictures and write a brief guide to construction. Most of the parts are stock so there is a lot less cutting etc to do.
My only concern, at this point is how durable the light weight components might be. They are so inexpensive that if parts do need to be replaced occasionally it should not be a big deal especially considering that they all screw together easily.
There is one other minor concern. The NEMA 24 motor has an 8 mm shaft and the perfect pulley has a 5/16″ bore. That means that you have to increase the pulley bore by about .0024″ or reduce the shaft diameter by the same amount. An 8mm drill bit adds a little to the cost and ideally the hole would be drilled in a lathe. The other option is to use a NEMA 23 motor with a .25″ shaft but i really like the bigger shaft of the NEMA 24. Not a size queen, just an engineer who likes to over-design a little.