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Old 09-15-2013, 02:27 AM   #214 (permalink)
mechman600
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Join Date: Jul 2008
Location: Langley, BC
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Fusion - '16 Ford Fusion Hybrid SE
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I got my new coupler back from my machinist friend, Matt. Once again Matt proved his brilliance and made me another work of art.

I quickly got to work installing the tachometer pickup sensor. The two bolts on the coupler will spin past the sensor, acting like the pickup that used to be in the distributor.
Why two bolts? Because this will be measuring "crankshaft" speed which spins twice as fast as distributor speed, so it needs half as many pickup teeth as it used to have.

Another bit of fabrication that I needed to do for my new motor is the right side motor mount. In the end I just decided to weld a bolt onto the bearing cover. It really doesn't look very strong, but since the transmission has three mounts, all this mount does is hold the motor in the correct position. There isn't much weight on it.

Today I put everything back together, except for tying up wiring because I ran out of zip ties. I then ran the motor for an hour at just over 2000 rpm to break the old brushes in. I figured it would be a good idea since I moved the brush holder, and I may not have got it perfectly centred with the armature.
Here is a video:
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