Ben Nelson's Electro-Metro Build thread

[bennelson]

http://www.youtube.com/watch?v=rzfxhFlrIDg

[TheSGC]

You don't happen to have the exact specs on the lovejoy couplings and spyder do you?

I am almost finished with my EV, but I stayed away from the lovejoy couplings because they couldn't handle the torque. At least the ones that fit my motor shaft couldn't handle it, so I had to design one and have it machined up.

The lovejoy connections seem to be measures in inch-lbs for torqure, so you should make sure that your coupling has a least 3500 inch-lbs for the least chance of things going wrong.

Now get that fixed so we can see more pics of the EV driving and not being towed!

[MetroMPG]

That's quite the coupler picture, Ben. I was going to waggle my finger and give you the hairy eyeball for not occasionally peering through the inspection window you purposely cut into the bell housing just so you could keep an eye on things!

But then I remembered I haven't looked through ours for quite ... some ... time.

But I will now!

In fact, e-mailing Ivan to show him what happened.

Hope it's not too hard - or spendy - to repair.

[bennelson]

Anyone just replace, or is about to replace the clutch on their Metro?

I could use your old clutchplate! I really only need the splined bit out of the middle for use in making a new coupler.

I really don't know for sure if I need a new transmission shaft splined bit or not, until I get the car apart, but even if I don't, it wouldn't hurt to have a spare!!!

[metroschultz]

I don't have one handy, but I think Coyote might.
I am going to the boneyard tomorrow (Today?) and will loook for an engine that has been left on the side of the road for spare parts.
S.

[bennelson]

I just pulled the motor out of the car.

The coupler is totally worn out. The spines on the motor shaft and motor half of the coupler both look good.

I can't get the transmission half of the coupler off the tranny shaft.

I am trying to pull the transmission next. That's a huge pain in the butt!!!!!!

[Tango Charlie]

Could you use an abrasive cut off wheel in a Dremel tool to cut it off?

[bennelson]

Yea! Got the transmission out!

Once it was out, I was able to get the coupler half off. It look lots of wiggling and prying, but it came off!

[MetroMPG]

Glad to read you're attacking the repair, Ben.

[bennelson]

Both halves of the coupler will need to be rebuilt.

The splines on both the motor and the transmission shaft both look good, but the splines on the tranny shaft coupler half are GONE! This is from the center of an old clutch plate, machined down.

That means I need to find a new donor clutch plate to make the new transmission half of the coupler!