Nikko's Jet Gale 91 upgrade to a mabuchi 540

thingiverse

WARNING: This project involves 3D printed parts spinning at high speeds, so be cautious if you decide to print it. Here's a modern update of my childhood toy, a Nikko Jet Galle 91. In the third photo, there's a comparison of the original motor and the Mabuchi motor - a budget-friendly option perfect for maker projects like this one. The design works seamlessly with the original propeller, consuming approximately 10 amps of power, which is roughly half of the potential output of the 540 motor. To boost performance, I've created two new propellers. Both share the same input angle and output angle but differ in blade count - three blades or five. While the five-blade prop remains untested, the three-blade version significantly increases speed. Its power consumption clocks in at around 22 amps. My design isn't without its flaws; it produces excessive torque, causing the motor to tip the boat sideways at high speeds. This constant rightward turn can be counteracted, but cornering leftward is noticeably worse. Another drawback lies in the prop's tendency to lose speed when waves bubble up and cover the blades - a situation easily resolved by simply readjusting airflow. Two videos showcase the performance of this model: First video: The original propeller: https://youtu.be/Nn-YDuAk7O0 Second video: My custom propeller in action: https://youtu.be/jxUaev8fVYs These clips highlight the mentioned issues, showcasing areas for improvement. Printer Details: * Brand: RepRap * Model: Prusa 2 * Rafts: Not essential for this project * Supports: A must-have feature due to prop designs * Resolution and Infill: Set at 0.3 mm Post-Printing: Building the cardan requires a set of five parts, starting with attaching two identical KardanKreuz2.stl components together using acetic acid, after which one KardanKreuz1.stl piece can be securely attached to create the base unit. Once completed, insert and connect Kardan2.0_3.stl, followed by assembling both ends of Kardan2.0_2.5.stl components. Then use two Mabuchi motor mounts and four wood screws to secure the assembly