Adventure EV

Fabrication

First EV related setback.

by on Nov.14, 2009, under EV Land Rover, Fabrication, Motor

I guess it’s been a bit quiet for the past couple of days.  There are a couple of reasons for that.

Turns out that the motor adapter pieces I have don’t exactly fit entirely.  The adapter plate itself isn’t the problem.  The bolt holes in that match up just fine with both the motor and the clutch housing.  The problem is with the flywheel adapter.  Basically, the flywheel adapter puts the flywheel at the wrong depth for my transmission.  You can see the difference (maybe) if you look at the two pictures.

Original Flywheel Mount

Original Flywheel Mount

New Flywheel Mount

New Flywheel Mount

The first image is of the original flywheel adapter on the back of the engine with the clutch housing in place.  The second image is the new flywheel adapter in place in the motor using the same clutch housing sitting on the motor adapter plate.  The clutch housing is the large cast aluminum case surrounding the round bit with eight holes, the flywheel adapter.  It’s hard to see, but the adapter in the bottom image sits farther away from the clutch housing.  Using this would put the flywheel and clutch completely in the wrong space when mounted to the transmission.

This is not entirely unexpected.  The adapter kit I purchased was for a Netgain Warp9 motor which turns out to have a different shaft length from my Kostov.  But until I could actually get the pieces in place, I didn’t know how different they’d be.  Luckily everything else seems to be the same… bolt holes on the adapter plate, etc.

Measuring the distance between the clutch housing and the top of the flywheel adapters results in a difference of 0.75″.  I have to reduce the depth of that flywheel mounting surface by 0.75″.  There are a few ways to go about this.  One solution is to cut the motor shaft down by 0.75″,but I don’t really want to mess with the motor. Another would be to shave 0.75″ off the face of the flywheel adapter, but that would leave too little of the adapter itself.  So, I’m opting for a third method.  I’m having a spacer machined to set the motor 0.75″ away from the adapter plate.  Here’s a mockup in Photoshop:

Motor spacer

Motor spacer

This adapter will sit between the motor and the adapter plate, essentially reducing the depth of the flywheel adapter within the clutch housing.  Again, much like trying to find a custom color of automotive paint, being in a small town doesn’t give me a lot of options when it comes to machine shops, but I eventually found one that will do the job for a reasonable price ($60), and I should get the piece on Tuesday.

Once I get the flywheel on with the clutch, everything may appear more evident.

This put some of the vehicle work on hold for a bit, since I can’t mount the motor without the spacer.  So I spent Friday down in Albuquerque buying bits of aluminum and steel angle iron for the four battery boxes that I need to fabricate.  More on that later.

If this is the only issue regarding the mounting of the motor to the transmission, then that’s fine by me.  However, I have to look forward to securing the motor in place by coming up with a motor mount that will work with the existing frame mounts.  More on that, too, when the time comes…

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