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The motor mounts are made from 2" x 2" x 1/8" aluminum angle. The large holes to clear the lip of the motor are cut with a flycutter before the part is cut from the raw stock. This helps keep it stiff while being worked. The large hole is 1" up from the bottom, based on the size of the motor and the desired position of the drive screw.
A 3/8" hole is drilled in the bottom. This is for the bushing that allows the motor to swing. The bushing is cut from 3/8" nylon rod stock, and is slightly thicker than the 1/8" thick angle. The 3/8" hole is reamed slightly with a hand ream to make the hole slightly larger on the top side. This allows the nylon to be deformed into the hole, pinning the mount to the base. A tight clearance hole is drilled in the center of the bushing to pass the screw. The screw is a #4 flat head screw. It deforms the bushing as it is tightened, capturing the motor mount, but allowing it to pivot slightly.
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