DIY EV Part 15 - Motor and Gearbox Coupler

[@blackterminal]

Could you please add the two fiat clutch discs you used in your video text description?

[@alibro7512]

I used two types and you can see them here at 7 minutes in kzbin.info/www/bejne/hXSbmKqVgMScaNE Blueprint ADC43101 and ASIN DE-7FI

[@stephendarbey5411]

Love the way you got the slack off the spline. Ingenius and so simple. In fact it is so good I 'm really jealous I didn't think of it. Keep up the good work.

[@alibro7512]

LOL, thanks but it was a combined effort between John Nodge and myself. We both had the idea but his implementation of it was much better and he did all the hard work on his lathe.

[@johnnodge4327]

It's so good to see it progressing Ali. I'm glad the coupler is working well too. I can't wait to see it in the car now.

[@diymicha4905]

Noice. I did much the same for my Golf 2 conversion, after the electric motor destroyed two clutch disks. I also put a switch onto the gear shifter knob to cut off the motors recuperation when I want to change gears. So the way to change gears is now: Press the cut off switch, let go of the gas pedal, change gears, step on the gas and finally let go of the cut off switch. Works like a charm. And the other most useful thing I did was to insert a potentiometer to the circuit to choose the grade of recuperation manually between 0% to 80% approx. And a little circuit that turns on the brake light when I let go of the gas pedal, and recuperation kicks in over 50% recuperation.

[@alibro7512]

If I ever get the bloomin thing working I'll try to do these things too. Baby steps for now. 😉

[@sveip]

Seems to be moving along nicely. Well done.

[@CASHSEC]

Hi Ali. I have sent Damien Maguire a note about new UK Government plans to tighten up on car modifications so called to keep cars safer but it might kill off home conversion. Consultation due to end around Nov 20 2021. Write to your MP to ensure Home EV conversion is allowed to continue. The work you guys are showing so much potential for future work and good for the environment.

[@alibro7512]

Damien is in the Republic of Ireland so it will not effect him. I'm in Northern Ireland which although part of the UK we have our own rules which may or may not be effected. Our local village idiots can't decide anything.

[@blackterminal]

We have rules in New Zealand and Australia also has rules but for the most part they are reasonable. Just the compliance test is expensive. We can't put batteries just behind to he radiator though. Has to be back a bit. Closer to suspension points. I just decided to put all my batteries in the back as they wouldn't fit otherwise.

[@alibro7512]

@@blackterminal I will have some batteries close to the radiator but most will be at the back.

[@TheAussieincalgary]

That's a nice compact assembly. 😎

[@alibro7512]

Thanks mate, so far so good but I still have to test it properly on the road.

[@CASHSEC]

You solution to remove the backlash was the way I saw it but you have considered also the hardness. The outer tube provides the extra strength to stop the shattering of the inner spline tubes. Interesting to see the back emf effect of shorting out the power leads and indicates how regen has to be limited. Something to consider is that if the power leads got shorted ok the main fuses would blow but the IGBT's in the controller may still hold the short if that is where the fault lies. This could lead to a lock up of the wheels. On a boat the prop usually has a shear pin. If your system retained the clutch you have a chance to disengage the motor to possibly regain control of your wheels.

[@alibro7512]

I'll try to ensure the power leads never short. 😉 as for the splines I'm not convinced they will last but will see. I'll not be doing burnouts. Retaining the clutch would have been beyond my skills to fabricate and I didn't fancy paying hundreds to get someone else to do it and maybe cock it up.

[@javierchaparro4769]

We used the same system here!

[@r.abhiram3072]

Hello Mr.ALi, I'm pretty impressed with your work. May I know some technical details about the adapter plate you used? and why that amount of thickness and why with the same shape of gearbox outer plate ? Can you tell the technical details about it.

[@alibro7512]

Hi and thanks for your questions. I chose 20mm alloy because I thought it would be strong enough for the job. I wasn't sure about 15mm and figured 25mm would be harder to work and heavier. The exact thickness was not critical as the adapter was made to match the plate thickness. I could have kept it square but cut it to shape to make it nicer looking and also to reduce weight. I hope this helps.

[@blackterminal]

Did you really have to remove that lip off your coupler or you just wanted to?

[@alibro7512]

Good question. With hindsight it may have given a stronger weld had I left it as it was but it was in my head that I had to make a V groove to fill with weld.

[@CASHSEC]

Dear Alibro. Have you sorted a way to get your project road legal. Initial investigation seems to be a nightmare and could cost a lot of money. The biggest cost seems to getting an electrical test. This is around £2000. Then the IVA test around £500 pounds. There are only two places in UK that do the electrical test. I don't know the latest situation and wether my facts are correct. If only there was a Web site that could lead one through the complete process. Next is the insurance. I see that you can get a used complete Nissan Leaf for as little as £4500. UK IVA test sites are listed on Gov web site. It's a minefield.

[@alibro7512]

Sorry I missed your posts. The KZbin system for seeing comments is pretty terrible. I'm not sure where you got this info as it is not what I have been told. Have a look through this thread. openinverter.org/forum/viewtopic.php?f=9&t=543

[@CASHSEC]

I scanned this and it also seems to point to confusion. I have read that it became more difficult around 2002 and cars prior to that went to 0 Road tax. After that point it would appear that EV Converted cars retained their original road tax. Yet the Nissan leaf is apparently rated 0 tax. In the end it is clear that for DVLA it is a minefield. The Government will want some form of Road tax. Vested interests of the big car companies will lobby to get home conversion banned.. So get your project done and get it cleared while you can. The whole future is a bag of worms. Lorries and buses may uses pantagraph to power pick up. Do we have enough power to run the show. Se la vie. I still love your work.