Ben Nelson's Electro-Metro Build thread

[TheSGC]

Definitely do not use the lovejoy! If you look up the specs on the L099, it has a max torque rating of 66 ft-lbs, which is nothing for an EV. Lovejoys for EV should only be used on 6.7 motors and smaller running 48 volts or less. Sintered Iron just isn't strong enough and I really don't think aluminum is either. I used stainless steel for my hub and so far so good.

[bennelson]

TheSCG, do you have any more specs on your setup?

I've been getting a little frustrated lately with people telling me what NOT to do on my project, but without adding any details of positive experiences on their conversions. (Not specifically picking on you here, just saying that most of the advice coming to me has been from the least experienced people in conversions!)

The latest info anyways, is that I am going to be trying out a SOLID FEMALE/FEMALE connection. Basically both female spline sections welded to each other by means of a small section of steel plate, turned on a lathe so that everything is centered and round.

Hopefully, this will work well, and I can get the motor installed this coming weekend.

[TheSGC]

What I have is essentially a clutch setup, with a stainless steel hub that has the bolt hole pattern of my flexplate for my automatic (aka clutch plate) and then a taper locking piece that has the 7/8 inch bore for my shaft, which is then bolted into my stainless steel hub. Here's a picture of it: S5001540.JPG (image)

Now since I did an automatic transmission, my design was the same as a clutch setup. If I were to do a conversion like yours and opted not to keep the clutch, I would do what you plan to do with welding the two female spline pieces together, but then I would place them into a tube and weld them again to the tube for maximum strength.

And here's the link to my conversion if you're interested: http://civicity.blogspot.com

[MPaulHolmes]

I have an L-95 lovejoy in a 72v superbeetle. I try to accelerate gently (actually I have no choice. hehe) It's working well so far, but I am pretty gentle with it. I have like 150 miles or some such so far.

[bennelson]

Originally Posted by TheSGC

I would do what you plan to do with welding the two female spline pieces together, but then I would place them into a tube and weld them again

Using a tube to jacket the coupler is something else we talked about. Not sure if it is really needed or not. Hard to say for sure without some real-world testing!

[TheSGC]

Originally Posted by bennelson

Using a tube to jacket the coupler is something else we talked about. Not sure if it is really needed or not. Hard to say for sure without some real-world testing!

I have no idea if it's necessary either, but I think it would be a quick check to see if the two halfs are lined up properly. Or it could end up being a whole lot of work for little benefit.

[bennelson]

I just added photos to post 716, so go back there to SEE what work we got done this past week on the Electro-Metro.

I just got word that Rich finished off the coupler for me. We ran out of time on Sunday working on it. Rich has both a lathe and a welder, so he said he would just finish it off for me!

The target now is to be installing the combined Motor/Coupler/Transmission back in the car this coming Sunday!

[MPaulHolmes]

Man, when Larry the Cable Guy said "get 'r done", you were his inspiration!

[Tango Charlie]

Ah! I think I get it now. You made a sandwich. The splined hubs are the bread and a layer of bar stock is the meat. Right?

[bennelson]

Yep.

The welds are the mayonaise!