I’m working on a non-eFoil project, but I’ve drawn a lot of inspiration from the direct drive threads on this board so I thought I’d share some pictures in case others find it interesting and/or useful.
I wanted a kaplan style propeller for use with an APS outrunner motor and, of course, there is no such thing available anywhere. So I made one. It’s designed to allow as much cooling water to flow through it as possible, with matching openings at the back of the prop to the ones on the rotor housing. The rotor slips inside with about 0.001 to spare and four M3 screws retain the prop to the mounting holes on the rotor.
It’s 7.5" in diameter and machined from 6061. The witness marks at the roots of the blades aren’t TIG welds - they’re from the contour machining operations.
Came out pretty well! Though I have a long way to go before I can test it…