Flywheel Removal Tool for Upcoming Open Source Flywheeler
I’m currently working on a mag-in-grip brushed flywheeler design that will likely be finished before Ragnaroktoberfest. There’s some features that I wanted to add to the flywheel cage that precluded the use of Flycore which set the standard for compact brushed flywheel design, and as I was already deviating from any established footprint, I figured that I might as well add some quality of life improvements to the flywheel cage.
One thing that bothered me was how modern flywheel designs don’t allow for the use of a gear puller (except for Kuryaka’s wheels, that’s why he’s the GOAT). The two holes flanking the motor wells seen on Worker’s and Kuryaka’s cages serve as access points for something to poke through and push the flywheel off the shaft, which works but leaves a lot of potential for error. Most likely the two objects pushing are made of metal, which can mar the plastic wheels we use. It’s also easy for the two objects to become misaligned, increasing the chance of slipping. As one is trying to push the wheel out while bracing the cage, they are also keeping in mind that pushing too far would risk damaging the fragile motor contacts.
The tool I designed uses 4 30mm M3 screws to evenly place pressure upon the spacer, removing any metal on flywheel contact. The middle is spaced for a motor to fit through with an inner rim impinging upon the outer motor can before the motor contacts protrude out on the other side of the tool.
This was intended to be used under a drill press with a 1.8mm steel pin in the chuck pressing down on the motor shaft to remove the wheel so as not to put any undue stress on the motor, but the old manual method can still be done as demonstrated in the video.