Electric Cutout Dissection
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My electric cutout seized, and was stuck open for a week
. Needless to say I was annoyed so I took everything apart.
![](http://i704.photobucket.com/albums/ww42/KirkEvil/NJFBOA/Cutout/IMGP0865.jpg)
The rubber boot that was supposed to weather proof the motor did a pretty good job of collecting water. The inside of the wimpy motor supplied with the cutout grenaded
. After opening it up, I was surprised it had no signs of failure before seizing up.
Anyway, I decided to upgrade to a bigger motor and show some pics of the inside of the gear box...
The Gear Box...
![](http://i704.photobucket.com/albums/ww42/KirkEvil/NJFBOA/Cutout/IMGP0868.jpg)
The inside...
![](http://i704.photobucket.com/albums/ww42/KirkEvil/NJFBOA/Cutout/IMGP0869.jpg)
Disassembled...
![](http://i704.photobucket.com/albums/ww42/KirkEvil/NJFBOA/Cutout/IMGP0870.jpg)
Mini gear carnage...
![](http://i704.photobucket.com/albums/ww42/KirkEvil/NJFBOA/Cutout/IMGP0875.jpg)
I pulled the input gear off the old motor and pressed it onto the new one, but the shaft was longer so it needed to be shimmed...
Old vs new motor...
![](http://i704.photobucket.com/albums/ww42/KirkEvil/NJFBOA/Cutout/IMGP0873.jpg)
New motor mounted...
![](http://i704.photobucket.com/albums/ww42/KirkEvil/NJFBOA/Cutout/IMGP0867.jpg)
Shows new motor with gear engagement...
![](http://i704.photobucket.com/albums/ww42/KirkEvil/NJFBOA/Cutout/IMGP0874.jpg)
Going back together, blue makes everything better...
![](http://i704.photobucket.com/albums/ww42/KirkEvil/NJFBOA/Cutout/IMGP0876.jpg)
I didnt feel like getting raped by the price of a controller, so I went with the radioshack special; DPDT switch (on the right)
![](http://i704.photobucket.com/albums/ww42/KirkEvil/NJFBOA/IMGP0848.jpg)
Since wiring cutouts can be confusing, I made a sweet diagram that may help some people out....
![](http://i704.photobucket.com/albums/ww42/KirkEvil/NJFBOA/Cutout/CutoutWiring.jpg)
The new motor opens/closes the cutout valve in about 2 seconds as opposed to the stock motor which took about 6 seconds.
I also picked up a sound measuring device from the engineering building
: I run pacesetter LT's, ORY, and a hooker aerochamber. Measuring device held at passenger door, about 3 ft. from cutout.
Surrounding Noise: 55 dB
Idle cutout closed: 64 dB
Idle Cutout open: 96 dB
Hope somebody finds this stuff interesting.
![MAD](https://ls1tech.com/forums/images/smilies/LS1Tech/gr_mad.gif)
![](http://i704.photobucket.com/albums/ww42/KirkEvil/NJFBOA/Cutout/IMGP0865.jpg)
The rubber boot that was supposed to weather proof the motor did a pretty good job of collecting water. The inside of the wimpy motor supplied with the cutout grenaded
![Ripped](https://ls1tech.com/forums/images/smilies3/ripped.gif)
Anyway, I decided to upgrade to a bigger motor and show some pics of the inside of the gear box...
The Gear Box...
![](http://i704.photobucket.com/albums/ww42/KirkEvil/NJFBOA/Cutout/IMGP0868.jpg)
The inside...
![](http://i704.photobucket.com/albums/ww42/KirkEvil/NJFBOA/Cutout/IMGP0869.jpg)
Disassembled...
![](http://i704.photobucket.com/albums/ww42/KirkEvil/NJFBOA/Cutout/IMGP0870.jpg)
Mini gear carnage...
![](http://i704.photobucket.com/albums/ww42/KirkEvil/NJFBOA/Cutout/IMGP0875.jpg)
I pulled the input gear off the old motor and pressed it onto the new one, but the shaft was longer so it needed to be shimmed...
Old vs new motor...
![](http://i704.photobucket.com/albums/ww42/KirkEvil/NJFBOA/Cutout/IMGP0873.jpg)
New motor mounted...
![](http://i704.photobucket.com/albums/ww42/KirkEvil/NJFBOA/Cutout/IMGP0867.jpg)
Shows new motor with gear engagement...
![](http://i704.photobucket.com/albums/ww42/KirkEvil/NJFBOA/Cutout/IMGP0874.jpg)
Going back together, blue makes everything better...
![](http://i704.photobucket.com/albums/ww42/KirkEvil/NJFBOA/Cutout/IMGP0876.jpg)
I didnt feel like getting raped by the price of a controller, so I went with the radioshack special; DPDT switch (on the right)
![](http://i704.photobucket.com/albums/ww42/KirkEvil/NJFBOA/IMGP0848.jpg)
Since wiring cutouts can be confusing, I made a sweet diagram that may help some people out....
![](http://i704.photobucket.com/albums/ww42/KirkEvil/NJFBOA/Cutout/CutoutWiring.jpg)
The new motor opens/closes the cutout valve in about 2 seconds as opposed to the stock motor which took about 6 seconds.
I also picked up a sound measuring device from the engineering building
![Icon Twisted](https://ls1tech.com/forums/images/smilies2/icon_twisted.gif)
Surrounding Noise: 55 dB
Idle cutout closed: 64 dB
Idle Cutout open: 96 dB
Hope somebody finds this stuff interesting.