Here are some upgrades on the mechanical part.
I was tired to have to re-tension the coated wire on the pulleys every approximate eight hours of gaming so I moved on to a permanent solution to this.
I bought two engine belts from a Mercedes BUS Parts store and place them on the pulleys. It turned out real pain in the ass because the belts I bought was 10cm longer (I could not find exactly 2meters long that I needed) and I had to add more pulleys to archive the proper tension.
See a short video of the job mounting it here: beltupgrade.wmv
I had to unbolt many, many, many bolts to pass the belt thru the pulleys! But the result was worth it!
The belt fits exactly on the large pulley that is mounted on the motor.
But on the smaller pulleys tracks it wasn't fit so well. They are small but they could still hold the belt from slipping on the sides of the tracks. And on top of that the belts were 10cm longer and I had to add another pulley to reach the proper tension.
So I added some pieces of dexion to hold this new pulley extension, again by using a large threaded bold and many bolts to secure the pulley in place.
Placing the belt on the pulleys turned out real hard job. But with the help of a screwdriver as lever managed to slip the belt inside the pulley's track.
Now its very stiff and durable to any fast motion of the motor. Its tension is so firm that its impossible to make it slide. In the photo below you can see the type of the belt (in case you seek a similar one)
After I powered the motor to check for any problems I noticed a terrible squeaking sound from the large pulley of the motor and decided to unscrew the whole thing to see what's happening. I found out that I was forgot to add locktite ring to the center screw that holds the pulley and it had unscrewed from the tension. So I took the opportunity to take some better photos from the insides of the pulley mount on the motor:
After mounting the belt I had to also hook the frame on it to have it follow belts up and down motion. After going to several hardware stores I finally found fairly large rope clips that could embrace the belt without stretching it much. It was nice that the bolt part of the rope clips could fit perfectly on the existing dexion parts holes! So I bolted the clip on a piece of dexion and the dexion was bolted directly on the frame's pvc pipe.
Here is a small video clip of the motion test results with the new belt:
... and the upgrades never seem to come to an end! More are about to come soon!
Thanos