Drawings finished....

So finally after a couple of months my drawings are finished enough for quotes from machine shops. Since sending them out I found a couple of missing dims and one dim I had to change but these won't change the quotes themselves.
I have sent them out to places all over to try and get the best price. This can be risky in that I don't know the reputation of some of the places but I'm hopeful it will work out ok.
It will take a couple more weeks to decide on a shop and once I give the go ahead a few more weeks at least waiting for parts to be finished.
I have other work to do while I'm waiting, embedding hall and temp sensors in the stators and prepping other parts. I've also been looking around for some old used car batteries cheap to test my electronics out, its proven to be difficult as even old virtually dead batteries have value for recycling.

Thanks to Tom Staub at High Plains Tool and Mold

My local machine shop didn't have the right tools to measure the stator dowel hole locations properly; so after some searching I found a website where some guys built a Honda Insight with a Tdi lupo engine. They had an adapter plate machined and so must have measured the dimensions I required.
Tom Staub at High Plains Tool and Mold (ph: 303-806-0451, 3201 S Zuni St # C Sheridan, CO 80110-1996) was happy to help and went to the trouble of finding his notes on the adapter plate. Thanks Tom!
Now I can proceed with finishing my drawings.

Design almost finished

I've made a lot of changes to the design, I managed to eliminate one part to save costs and simplify some of the others.

I have a small amount of CAD work to finish off and then tidy up the drawings and tolerances. I have one motor at a machine shop which is being measured to check my dims.

Both motors have cooling tubes

Finished off the second motor, just need to add temp sensors and hall sensors and they are complete.

Offset dim

Pics for offset dimension question on samba forum.

One motor almost finished

Mixed 7oz of silicon RTV with 1lb of iron filiings, it mixed in quite easily. Used latex gloves and applied it to the pre-formed copper tubing wrapped around the stator. I had previously machined in clearance on various places using a dremel etc.
It was tricky to do but I have it finished, I used two zip ties at the tube outlets to hold them in place before adding a lot of pure silicon to prevent the tubes moving around.

Heat

I have decided to water cool my stators in the motors; they are not designed for continuous use in the honda cars so they may get too hot in my EV.
I'm going to use a double wrap of 1/4" copper tubing with an ethylene glycol and water mix pumped with a home computer water cooling pump; the pump will flow around 1 gallon per minute at its maximum output.
There are two places I can add the copper, I can try and cool the copper coils themselves which is where the heat is generated or the outside of the stator assembly itself. I considered trying to cool the coils but I'm afraid whatever solution I come up with is going to risk damaging the coils, even if I get everything mounted ok its possible the tubes may rub and vibrate and wear through the insulation and create a short over time.
I'm going to wrap the outside of the stator assembly instead, I was going to purchase thermal insulation gasket material but its too expensive in the quantities I need for my EV ($300) so instead I'll either silicon them in place or epoxy.
To increase the thermal conductivity of the silicon/epoxy it would be nice to load it with particles that are highly thermally conductive, powdered copper or aluminum would be best but might be tricky to find or be too expensive. I'm considering using talcum powder instead which is magnesium silicate. I found a lot of data on talcum powder and I never knew it was actually a carcinogen, if I use this I'll be taking care to avoid handling it or breathing it in.

Edit: I found iron filings are cheaply available and only cost around $5 a pound, they are also non toxic and should be easier to mix with epoxy or silicone. I bought 3lbs online and they should arrive next week.