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I made 55.19 all across the surface. But, the ID of my coolant manifold indeed different top to bottom. I just thought the fit will be more tight on the bottom, which isn't bad :)

After some hours on the lathe and a couple of unsuccessful caps, I've finally made a proper one and press fitted it for my future rebuild. The problem was in the inconsistency of the ID. On my part the surface is more like oval, and the ID also different on the top and bottom of the groove...

Yes, it is still in the development. I will share the CAD file once it will be reliable enough. Today I've got isolation error on my Model S, so I need to do a rebuild asap...

I think it really depends on the cap design. If this will be a hollow cap made out of bent thin sheet metal (similar to the Chenming design but w/o hole) this would be possible. In case of a solid machined steel cap it will shrink/expand by approx. 0.05mm (depending on the alloy) for 100...

I've done a couple of measurements with the Mitutoyo bore gauge, and it seems that the surface is actually conical (at least on my part), and not super precise. The cone could be a result of deformations after the seal replacements in the past (it was replaced at least 2 times). The inner...

Not yet, but I have a high mileage Model S w. LDU, and the issue will appear sooner or later. I am preparing myself :) Thank you for your advice, I actually was thinking that the inner diameter for the seal is 55.2, but now I measure smth around 55 (will make a precise measurement later). I had...

So, small update: After some thinking, measuring and testing I've ended up with the idea of a design, similar to QC. Mine is just a bit more simple and could be done on a 2D (CNC) milling machine to make it cheaper and easier. Also, following the cap idea discussed before, I did a drawing with...

It all really depends on how one run the motor. I believe that the "wet" approach with cooling the rotor is more solid, i.e. covers the most of the usecases. It is still unclear how much heat is produced by the rotor on various power loads for the LDU. I believe there is an upper threshold...

I can also speak Polish if needed, and would be interested to join your conversation :)

Thanks for the photos, indeed I think the bottom hose connector could be moved to the top. I would tend to not block the gearbox input completely, since this is too much of a customization from my point of view. I personally don't know 100% what is the function of that coolant loop and would...

So, I did a preliminary design of the parts. The idea is to completely replace the rotor cooling tube (1006606-10-B) with a pair of parts. The lower part is basically just a feedthrough to the stator and the bottom 8mm hose connector. The upper part has the the vertical channel to feed the...

Hi folks, I've just stumbled upon this thread looking for a good solution to repair my LDU. And I'm thinking of creating a pair of parts to replace the rotor cooling tube - similar to QC Charge mod, which I find a bit complicated from the fabrication point of view. I explain it on the photo of...