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Old 03-11-2008, 11:54 PM   #216 (permalink)
MetroMPG
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Location: 1000 Islands, Ontario, Canada
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Blackfly - '98 Metro
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We ground the splined hub out of our clutch,as you're considering doing, and welded it to one half of a lovejoy type coupler. We welded our stub shaft to the other side of the lovejoy.

If I were doing this all over again, I would consider keeping the clutch and a cut down flywheel. While clutchless shifting isn't impossible, it does grind more in cold weather (a thinner tranny oil might help), and getting in & out of gear frequently (to coast in N, as befits a hypermiler) is easier with a clutch.

But keeping the clutch complicates things because your motor then also has to take a thrust load, which it may not be designed to do.

Because your "stub shaft" doesn't insert as far into your pump motor as ours did, I think you're right to consider setting up some kind of bearing assembly to hold it centered in place.
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