David's 2001 Civic EV (80-100 mile range; 65+ MPH; 8 second 0-60)

[TheSGC]

Well my motor shaft has bought the farm.



We have come to the conclusion that the coupling was loose because of rust on the inner taper locking piece when we assembled the EV. When we took the transmission out I found the flywheel loose on the shaft!

I tried calling around but I could not find a motor shop to repair it so I am calling up EV suppliers to see who has a Warp 9 in stock. I am going to put a brand new motor in my EV and then I am going to locate a machine shop to turn down the shaft to a slightly smaller diameter, replace the bearings and sand down and repaint the case. I figure the rebuild will be over a few months to find everything so I am buying a new motor so I can get running again. And this time we are getting everything balanced before it does back into the EV.

Oh, and I still need to rebuild the transmission. I have everything to do it except the space, so this weekend is the way overdue cleaning of the workshop.

[NeilBlanchard]

Bummer. Electric motors have a bunch of torque!

[mechman600]

I wonder if you could clean the shaft up really good and have a machine shop make up a coupler that fits really snug to weld on. You don't really have much to lose at this point.

[TheSGC]

Originally Posted by mechman600

I wonder if you could clean the shaft up really good and have a machine shop make up a coupler that fits really snug to weld on. You don't really have much to lose at this point.

I am going to buy a new motor just to get back on the road, but I am going to try to get the machine shop at my university to try and make the shaft usable again. If I can get it turned down to 1" diameter or even 0.875" it will be perfectly usable again. Thankfully there isn't too make damage to the shaft itself, I will need a new key way but that shouldn't be too bad. Actually I don't really need one cause I use a taper locking setup.

[adamj12b]

Originally Posted by TheSGC

I am going to buy a new motor just to get back on the road, but I am going to try to get the machine shop at my university to try and make the shaft usable again. If I can get it turned down to 1" diameter or even 0.875" it will be perfectly usable again. Thankfully there isn't too make damage to the shaft itself, I will need a new key way but that shouldn't be too bad. Actually I don't really need one cause I use a taper locking setup.

Just have them skim cut the shaft to the next size taperlock you can get like 1.06245 then, have them open the keyway to overcome the marred section and then machine a new custom key thats shaped like a T. The larger size fits in the new keyslot and the smaller section is 1/4" for the keyway.

-Adam

[TheSGC]

Originally Posted by adamj12b

Just have them skim cut the shaft to the next size taperlock you can get like 1.06245 then, have them open the keyway to overcome the marred section and then machine a new custom key thats shaped like a T. The larger size fits in the new keyslot and the smaller section is 1/4" for the keyway.

-Adam

I am thinking exactly that, I just need to get some quotes. EV America quoted me $615 + shipping for a whole new armature which didn't seen too bad. I am now waiting a a shipping quote and time estimate cause I can't afford me EV off the road for more than 3 weeks.

I am hoping to do a full breakdown of my FB1-4001a and check all the windings, brushes and holders before investing in a full repair.

I am not the original owner of this motor and after we took apart my coupling last night and found extremely little damage I am starting to expect some issues were created with the owner by the original owner.

[TheSGC]

My Warp 9 is on it's way! I ordered it up around lunch time today from EVA and if I am lucky it will arrive Friday or Monday!

In the mean time I will get at the transmission rebuild in a day or two after I continue the adventure of cleaning the workshop.

[Daox]

EVA?

Also, if I might ask. What was the shipped price?

[TheSGC]

Originally Posted by Daox

EVA?

Also, if I might ask. What was the shipped price?

Electric Vehicles of America. I'm getting it to my house for $2,060 total. I'm pleased with working with Bob Batson, between emails and phone calls today.

[Cobb]

Problems like this would make me toss in the towel. Glad to see it hasnt gotton you down.