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Originally Posted by AXMonster
I'm guessing some kind of external bearing on an extension from the gearbox may be in order?
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Probably mount something on the modified stamped steel cover and you'd be OK.
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Is that enough reduction??
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I can't really say with any confidence. I only know enough to say that it's something that needs to be considered.
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Also would the motor be able to handle higher voltages?? Estimated power output of motor? Top speed of a (currently) 1500 lb car?
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Probably. If the rating on the motor tag is continous, then you can absolutely feed it higher voltage/current for shorter periods. If you want to exceed its rated voltage/current for an extended period, you'd have to add forced air cooling however.
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Here's another question/thought: does the 5th gear cog have its own shaft, or are there other gears on it, inside the transmission case?
If there are lower gears on a shared shaft, I'd consider driving that one instead of the output shaft to the differential, because it would give you the option of multiple ratios. (Although the tradeoff would be that you'd have to have the clutch depressed to keep from spinning the engine via the transmissions "input" shaft while driving electrically.)
This idea fascinates me...