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Old 11-23-2008, 09:36 PM   #691 (permalink)
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Old 11-28-2008, 11:49 AM   #692 (permalink)
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Ben, looking at the damage from that latest video, and the way the lovejoy failed, I wonder if the clutch hub splines were sheared off by excess play.

As the lovejoy was wearing and the amount of play between the two halves was increasing, the motor would "wind up" a bit before smacking the transmission side hard every time you hit the accelerator, transferring a lot of torque onto those splines. THEY CANNA TAKE IT, JIM!

Just a thought. Bummer!
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Old 11-28-2008, 12:23 PM   #693 (permalink)
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Were both halves of the Lovejoy firmly sandwiched all the way together? If you are using a tapped hole with an allen head bolt to hold the lovejoys in place on each respective shaft, could one have loosened and the lovejoys slid slightly apart, causing way more stress on the lovejoy teeth and spider? Even a couple millimeters would transfer the whole force to a smaller piece of the spider. Also, once there was some wear, like Darin was saying, each acceleration was like a running start for motor lovejoy teeth to bash into transmission lovejoy teeth. That could explain why the clutch plate spline was stripped too, because it isn't meant to have running start bangs, but a smooth increase of force.

That guy in New Zealand had a problem with the bolt that was supposed to hold the coupler to the transmission shaft. Also, the guy from Mississippi, Norm, that has like 63 videos on youtube of his EV conversions had a problem with the lovejoys separating some. He suggested to me that I re-tap the lovejoy hole, with a larger diameter, and add another tapped hole 180 degrees around the same lovejoy half.

I noticed that the $300 curtis (maybe all curtis) starts with a bit of a jerk each time, so that doesn't help, either. (or is that just mine?)
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Old 11-28-2008, 12:35 PM   #694 (permalink)
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I think there was too much play AND misalignment.

The idea of tapping a second allen screw hole on the opposite side of the coupler has merit. I noticed that tightening down the set-screw would actually throw the coupler off center a bit.

I have also heard of using the permanent Loc-Tite to position the coupler in the right spot.

Most controllers can be adjusted to not give to much force right away. I did finally get my new pot box (throttle) which I am hoping will give much smoother controller over acceleration than the forklift pot box did.
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Old 11-28-2008, 01:20 PM   #695 (permalink)
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Our lovejoy separated slightly as well at one point, and that allowed the motor half to go out of alignment (since it just floats inside the female splined motor shaft) and rub on the motor cap, wearing both pieces slightly.

We took steps to prevent that again - with a spacer inside the female shaft, loctite & jbweld.

Also, I sometimes used to be able to hear a very small amount of running start "slap" which I figured was in the motor splines. The jbweld fixed that up. Quiet power on/off transitions now.

You guys with your GRRR POWER 72v 300A cars have to be more careful than the wimpy ForkenSwift though.
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Old 11-28-2008, 01:29 PM   #696 (permalink)
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A set of snap ring grooves cut on the input spline of the tranny will hold the coupler in place. I could do it at home with a home made fixture but you absolutely need a sharp corner on the botton of the groove to make it work. If you do it with a set screw, be sure to drill a dimple in the input shaft so it will not work loose due to slight misalignment. Locktite it!

Do you still need a clutch hub??? I am looking thru my pile of spares...
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Old 11-28-2008, 01:52 PM   #697 (permalink)
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I have 2 clutch disks...can someone call Ben and tell him to check his private message? My cell phone number is on it. I'm ready to box and ship them at my expense TODAY if I get the go ahead and an addrerss.... Kim
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Old 11-28-2008, 02:01 PM   #698 (permalink)
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Quote:
Originally Posted by kimer6 View Post
I have 2 clutch disks...can someone call Ben and tell him to check his private message? My cell phone number is on it. I'm ready to box and ship them at my expense TODAY if I get the go ahead and an addrerss.... Kim
You EV people are so kind!!!!! It makes me just really feel in the Christmas Spirit!!
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Old 11-28-2008, 02:21 PM   #699 (permalink)
EV test pilot
 
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Join Date: Jan 2008
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Electric Cycle - '81 Kawasaki KZ440
90 day: 334.6 mpg (US)

S10 - '95 Chevy S10
90 day: 30.48 mpg (US)

Electro-Metro - '96 Ben Nelson's "Electro-Metro"
90 day: 129.81 mpg (US)

The Wife's Car - Plug-in Prius - '04 Toyota Prius
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Kimer6 is sending me his old Metro clutch disc hubs!

In fact, he's even donating shipping to the project!

Thanks Kim!!!

Much Appreciated!
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Old 11-28-2008, 04:41 PM   #700 (permalink)
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Ben, 2 splined hubs are on their way overnight Express....Merry Christmas! ...Kim

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