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I was always curious to try mounting a small outboard motor to a paddleboard. This would also be a great opportunity to improve my SolidWorks proficiency. I first created an adapter to fit to the mounting location of the board's detachable fin. I decided to use a bilge pump motor for this project since it is already internally water-proof, so all I needed to do was design a shroud for it that integrates seamlessly in a fin. I designed the entire assembly in SolidWorks to be 3D-printable. There is internal wire routing channels for the power and ground connections to the motor.
The motor propeller is designed in several parts so that the shape of each blade can be accurately 3D printed in a standing orientation on the print bed to achieve the highest printing precision. The blades were modeled with a loft between several cross sections of airfoils with guiding curves to define the overall shape. I then used a twist modifier to result in some "cupping" in the blade's shape, which is a subtle feature that increases propeller performance in the water.
The motor shroud and fin was printed in several parts in order to minimize the use support material. I designed each part to have a lip/groove on the mating surfaces to eliminate gaps between parts. This could then be sealed with silicone-based sealant for increased water-proofing. The blades were suspended inside a plastic tub containing acetone. I used the acetone vapors to smooth the surface of the blades, resulting in a glossy surface finish that minimizes induced drag in water.
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