Introduction: Halloween Zip Line - H.Z.L. (Axworthy) Ghost
This is a drive motor and pulley design for the HZL that is for light ghost on a relatively flat line along its path. There are many other sip line examples out there, mostly under the name Axworthy Ghost. This design is for those who want to keep the motor, assemble and pulley nodes small. The intended layout must be flatter and have relative little tension/weight in it's end running state.
The primary focus for this instructable is the motor assemble but I will also touch on nodes of the system because they all use the same design principle of allowing the pulley angle (plain) to dynamically change with the main zip line angle on entrance and exit of the weight of the ghost or any object you want to run (reasonably light). This approach solves the issue of setup and run where the line finds the bottom edge of the pulley (often a bike tire) and rolls itself off. Because of this approach I have found it easy to downsize the pulley to a modified plastic clothesline pulley.
Step 1: Select Your Motor
Two key items to acquire before you start it the motor and compatible mounting brackets. The 3D parts for this project are designed to work with the motor and bracket I bought off Amazon.
Amazon Link: Motor https://amzn.to/2mzlupa
Amazon Link: Mounting Bracket https://amzn.to/2LeFDiV
While I'm not an electrical expert I did buy this motor controler (https://amzn.to/2LrYdUe) and so far it has worked fine.
Step 3: Additional Materials
Motor Assembly Fasteners based on the 3D printed brackets:
3D printed Things: https://www.thingiverse.com/thing:3017107
M3 x 0.5 mm hex nuts https://www.mcmaster.com/#92497a200/=1dtp94f
M3 Screws - https://amzn.to/2LyW2OL
Eye Bolt and Nut - https://amzn.to/2Nxkg9p
Pulleys - https://amzn.to/2LIyfJ5
Step 4: Understanding the Nodes (non-motor)
The same clothesline pulleys can be used for what I call the "nodes". You will need to cut off one side (bottom) so that the "drop line" can pass around the pulley. I use a bent eye bolt that the pulley basically just hangs from. Many people online build their Axworthy Ghost by mounting to trees or homes. For my nodes I used 1" conduit to elevate the zip line above 8 feet and also offset the pulley from the pole so the ghosts do not wrap around anything as they sway in the wind making the turns.