This is a rough mockup of what I'm thinking I'll do for a hall mounting solution for a CEV stator/flywheel. The design utilizes the mounting point for the mechanical points which are no longer needed.
The working part will be cast out of urethane with an encapsulated hall sensor within several millimeters of the magnets in the flywheel.
 |
| Top view of encapsulation showing footprint of 3D printed dummy/mold negative. |
 |
| Sensor lead will protrude through the nub and out the stator through an existing hole. (3D printed dummy/mold negative) |
 |
| Casting is perfectly sized to lock an M3 nut through old points threaded hole. Uses pivot point of the points to fix orientation. |
 |
Hall sensor -> 3.5mm audio 3 pole used for the trinket ignition from this post:
http://deadped.blogspot.com/2014/03/trinket-arduino-dynamic-timing-video.html
|
Casting was a success!
The main thing I've been working on though is perfecting a process to etch my own double sided boards at home. I've had pretty good results and been able to use .12" traces, get them to effectively transfer and be continuous once etched. Right now I'm waiting on PCB drills so I can connect traces when they change sides. The bits I had didn't last very long, so I've got a set of carbide PCB bits on the way. Home etching for 32TQFP packages is doable! Biggest thing I had to do was increase the pad sizes for through hole transfers. Because of that, I'm likely going to have to eliminate the ISP header traces from the production boards.
