Well, Friday, the gasket came out ok, but when I grabbed and pulled on the edges, they came off easily. So I pulled off and scratched the whole thing, and saved this part for later. I know it works, I will just have to sand that area harder next time for better adherence.
Saturday and Sunday, I worked on the motor mount. I decided to make something similar to this one here, so I got some aluminum sheets, liquid bolt lock, and many Allen head M2, M3, and M4 bolts from the hardware bazaar in Karaköy.
I designed the part in SketchUp as always. The final form probably will not look like this.
I mounted a printed copy of the design above on a 1.5 mm thick, 35 mm x 45 mm aluminum sheet for easier drilling. I stilled counted turns on the hand-wheels of the mill to be sure though.
It was too late when I got to Karaköy on Saturday (most close at 14:00), so I couldn’t find thin steel brackets with slots (and I thought I’d be content with what I got in stock at home, and the aluminum strips I could cut from the 1.5 mm plate). The lightest and most suitable part I could find to use for the side brackets was a 1 mm thick steel corner bracket (I was hoping to find more of these in Karaköy), which I flattened in the vise and cut in half to make two side brackets.
I had to open two more holes (M3 this time for easy adjustment) for the side brackets, since the holes in the motor plate were too narrow for the forks (I ended up with, after the cut in the middle of the bracket. I wish I had one more) with holes.
It was time to bend the forks to 90 degrees. I used the bolted motor plate to align the forks in the vise. Then I removed the bolts and the plate, and hammered the fork down to 90 degrees. Did this for each side bracket. No motor width adjustment for this cheap copy.
It wasn’t too late when I realized the side bracket would be too narrow for the water nipples of the motor’s cooling jacket. I thought the plate was a bit thin anyway, so I added another wider layer for support. I taped and bolted the motor plate to a bigger plate for the cutting, milling, and drilling.
The motor plate is now about 56 mm wide and 32 mm high (motor diameter is 29.1 mm, water nipples stick out to 11 mm). I aligned the holes of the side bracket on the support piece using the vise as seen in the picture below.
I temporarily bolted the side brackets and the motor (with the 3.2 mm to 4 mm coupler on the shaft) on the plate for a test shot. Here are some pictures below, shot from different angles. It would be nicer if I had suitable a flex shaft collette, but this double setscrew coupler (pressure from both sides for better alignment) should do..
I will probably work on the plywood rails and the assembled metal parts tomorrow evening.