How to assemble the pulley on the car wiper motors:
The most important part of the simulator is its motion. To move my simulator I used simple 12volt car windshield wiper motors. The model that I selected was B-11 from Nissan 85'. Its important that it have its arm with the ball joint when you purchase it. The ball joint can be removed by drilling it off the rest of the arm leaving a hole to fix a bolt there.
(Again the photos in this section are a low resolution too cause they are taken almost a year before I finished the project, ...old camera etc)
To be able to fix a pulley on it you must use an intermediate plate that keeps centered the pulley to the motor axis. This must be done since there is no other easy way to fix the pulley plate directly on the motor axis as the nut that holds the arm leaves no space at all! As you can see in the pictures the intermediate plate I used is very thin and smaller in diameter than the motor fix points.
The idea behind this is to have the pulley part centered with the motor rotate axis and in the same time use its existing arm to do all the hard work of rotating the pulley. For that I drilled four holes in the intermediate plate that are perfectly centered and another four holes on the pulley part. A fifth hole is required on the pulley part so you can bolt the motors arm on it too (this is very important).
And some more recent photos showing more details (click on them):
To fix the pulley on all five bolts in equal height I used spacer nuts. This is also important to leave the motor fix points clear to mount the motor easily later. Place a little longer bolts in the four fix points to be able to fix on them a caster wheel mechanism with the wheel removed. The caster mechanism will counterbalance the forces of the cable tension in the pulley cable system. If you haven't done so use the caster wheel base to make the measurements for the four holes.
This is the picture of how it must look to be ready to mount the motor to the pulley system. The extra caster that is attached on the pulley will hold the axial forces from breaking the gearing of the motor. There is no need to bend the caster forks in this case.
The above procedure requires some skill with the electric drill to place the holes evenly. I used the caster holes as reference since I'd had to bolt it on too later. It took me almost day to measure (twice and some times more) precisely the holes on the pulleys to get them aligned with the motors axis center.