Sparky, The Electric Vehicle (EV)

Electric Vehicle Project: Motor/Transmission

7/23/2006 Motor<->Transmission Coupling--
I finally had the adapter plate cut to size. A neighbor, Dennis Green, helped out with this. He had the proper band saw in his garage to do the job (along with a mill, drill press, lathe, etc.). I left some material on the plate and drilled holes for hooking up the cherry picker. These holes can also be used for torque rods if need be. I lined up the motor coupler using an alignment tool. This centered the adapter plate allowing me to mark the bell housing perimeter and the mounting holes. Once marked, I drilled the holes and then had Dennis cut the plate. I Attached the coupler, leaving 1/8 inch spacing between the coupler and the motor body. The adpater plate was then bolted on to the motor. The remainder of the coupler followed along with the remanants of the clutch disk. We then bolted the adpater plate/motor to the transmission. The results are shown in the pictures below:

8/20/2006 Motor Install--
Another Milestone was accomplished today! We (Tina, Chris (my son), and myself) lowered the motor/transmission assembly into the vehicle. What a job!!!

Thankfully we had an engine hoist to help out. We lined up the ears on the motor mount bracket and then drilled them. We ran into one interference issue.

I did not have the adpater plate tapered at the bottom. I found that the corners bump into the frame where the rear of the front suspension attaches to the frame. I will have to cut the adapter plate in situ.

The plastic boxes for the batteries were also completed this week. I will be installing them next weekend.