DIY EV Part 7 - Chopping the Friction discs. Please skip to

[@sagster]

That's an interesting solution, I like it!

[@johnnodge4327]

The rough centre looks like a rough forging, but the machined one appears to be machined from a billet (it could also be a forging, which has been machined after forging). As to the durability of each, it depends on what forging process was used on the forged one, and what grade steel was used in the machined one, if it's a billet. You can get an idea of the hardness of each, simply by dragging a metal file across both, and see which is marked the most. My guess is the forging will be harder, and probably more durable.

[@alibro7512]

Thanks John I hadn't thought of it being forged but like I said in the video I am no expert. If the rougher one is better then that is good as it fits better too so I'll just carry on and use the rougher one for the drive and the second one for regen. I can't really take this any further until I get the gearbox out of the Freelander so the next step is to do the hard bit and get the electronics working.

[@alibro7512]

In this video the guy showed how he did it so I decided to copy it and see what happens. kzbin.info/www/bejne/aGSVomOBrc-Ajdk In the video I mention using the 3D printed part as a template but what I really meant to say was I will be able to convert the STL file used to create the 3D printed part to a DXF file for the water jet cutters.

[@jaredkomoroski]

There are cad exact diagrams for the splines. Couplers from these cad files have no play. But, As you said, it's only a leaf motor so it's not that powerful.

[@alibro7512]

Have you a link to them?

[@jaredkomoroski]

@@alibro7512 github.com/angusjo/leaf-splines One of those files is just a cylinder with the splined hole

[@alibro7512]

@@jaredkomoroski thanks for this, I will take a look at it and see if it will work with a Gen1 Leaf motor.

[@jaredkomoroski]

@@alibro7512 is that EM 57 or EM 61? I was thinking you were using an EM 57.

[@alibro7512]

@@jaredkomoroski No mate, it's an EM61 from a 2011 Leaf.

[@lumberjackdreamer6267]

Could you use the Leaf gearbox input shaft? It would be the perfect fit.

[@alibro7512]

You are right about that and if this fails I will go that way. I wanted to keep the Leaf transmission intact as it may get used for another project in the future.

[@lumberjackdreamer6267]

@@alibro7512 Thanks.