Thrustmaster wheel hub for Hoverboard motors

This design allows you to mount a Thrustmaster wheel to your hoverboard motor for use as a BLDC FFB sim wheel. It should suit most motors, hover due to numerous different designs on the covers, it cannot be guaranteed.

Information on the BLDC FFB Wheel/FFBeast project can be found on the author's github:
Hoverboard FFB Github

Includes:
- Template for drilling the hoverboard motor cover
- Wheel hub for mounting to the hoverboard motor cover
- Adapter shaft for mounting Thrustmaster wheel
- Locking ring for locking Thrustmaster wheel to shaft
- Mini-din plug holder (if wiring up the buttons for the Thrustmaster wheel.
- Slip ring inner shaft

Hardware required:
- 4 M3 x 25mm socket head bolts: for securing shaft to wheel hub
- 5 M6 x 10mm socket head bolts: for securing wheel hub to hoverboard cover (if tapping threads into the cover)
- 5 M6 x 15mm socket head bolts + nuts: for securing wheel hub to hoverboard cover if NOT tapping threads in the cover
- 2mm OD bicycle spoke approximately 200mm long. Each end should be filed flat to for half of the diameter of the spoke so that it has a flat face.
- 22mm OD x 17mm 6 wire slip ring (must have 7mm OD through hole Example Slip Ring

Pre-requisites:
- Disassemble the hoverboard, remove the motor and remove the cover from the motor.
- Drill the hoverboard motor shaft with a 9.5mm drill bit the whole way through.

Instructions:
1. Centre the "5 Hole Drilling Template" over the motor cover. Use the windows in the template to ensure its rotated to the best position for drilling.
2. Using a 2.5mm drill bit, drill out the 5 holes in the star pattern and the centre hole.
3. Remove the template from the motor cover.
4. Use a 5mm drill bit to enlarge the 5 holes you just drilled around the outside of the motor cover, then tap the holes with an M6 x 1.00mm pitch tap.
5. Using a stepped drill bit, enlarge the centre hold in the motor cover to approx 25mm diameter.
6. Feed the wires from the INSIDE ring of the slip ring, through the top hole on the "Slip Ring Inner Shaft" and out through the larger opening at the bottom, while sliding onto the slip ring.
7. Insert the slip ring and adapter into the motor shaft, feeding the wires for the slip ring all the way out the other end of the motor shaft.
8. Re-attach the motor cover to the motor, being careful to feed the slip ring and wires through the large centre hole of the cover that you drill in step 5.
9. Insert the bicycle spoke into the centre of the "TM Wheel Hub - 5 hole". This should be a friction fit.
10. Feed the 6 wires (3 on each side) from the outer ring of the slip ring through the two small holes on the inside bottom of the "TM Wheel Hub - 5 hole" and feed them up through the centre of the shaft.
11. Centre the "TM Wheel Hub - 5 hole" over the motor cover and press fit on and over the slip ring keeping the wires coming out of the shaft tight so that they dont get piched when inserting the slip ring.
12. Bolt the "TM Wheel Hub - 5 hole" to the motor cover using the M6x10mm socket head bolts.
13. Place the "TM Lock Ring" over the wheel hub with the open end facing outwards.
14. Attach the "TM Shaft" to the hub using the 4 M3x25mm socket head bolts, threading the slip ring wires up through the opening in the TM shaft.

Wiring instructions for the thrustmaster wheels can be found on the linked projects github. How you choose to connect the slip ring to the mini-din connector is up to you.

Example Print Settings:
- 5 Hole Drilling Template: 0.2 layer height, 15% infill, 4 layers/perimeters
- TM Wheel hub: 50% infill, 6 layers/perimeters. printed at 45 degree angle with s to add strength/reduce risk of breaking on layer lines
- TM Shaft: 50% infill, 6 layers/perimeters.
- TM Lock Ring: 0.2 layer height, 15% infill, 4 layers/perimeters
- MiniDin Plug Holder: 0.2 layer height, 15% infill, 4 layers/perimeters
- Slip Ring Inner Shaft: 0.2 layer height, 15% infill, 4 layers/perimeters

3MF attached for example print bed layout.