EV Dodge Neon Conversion

[bennelson]

Hi Everyone!

My new friend Tom G. is converting a Dodge Neon to be a 300+ volt AC electric car.

We are going to be making videos showing how to do a car conversion, and post them on YouTube.

I will start off by embedding videos here.




Perhaps we could get a LoveJoy sponsorship out of this one!

[MetroMPG]

Great idea, Ben!

I have to repeat a tidbit a professional EV builder told me a week or so ago, which was a warning against using Lovejoy couplers in high powered conversions. He seemed convinced they would wear out the spider. I can't say whether that's true or not, and didn't think to quiz him on what type of spider material he was talking about.

[Daox]

Meh, as long as the coupling is big enough (or designed for the torque) its fine. We use generally the same type of coupling in the conveying industry and we're transmitting thousands of ft/lbs of torque.

[MetroMPG]

Meh, I stand corrected then.

I have heard of a lovejoy failing on a low-power EV though (72v). Can't say why, of course.

Ben's going to become famous with his video series. His friend Tom, too.

[bennelson]

This is, of course, just the first of many videos.

Comments like asking if a Lovejoy coupler works or not are all appropriate questions.

A big part of these videos is to encourage discussion of vehicle design, and encouraging others to get out there and do it!

[Daox]

Well, I can't speak for the love joy specifically. Ours are a bit different in design and are made to handle the torque (up to 11,000 ft/lbs or 15,000 Nm).

rexnord.com | Wrapflex

[captainslug]

I wouldn't worry about the Lovejoy so much as I would relying on such a small end-face seam weld for power transmission. It might be more prudent to use a larger spline size lovejoy and lathe it to match a slightly larger size, then mill the spline adapter to include a keyway.

Of course that really depends on how much force it took to press the spline bushing into the lovejoy before you welded them together.

Relevant project link where the motor and transmission were coupled by interference fitting a spline adapter onto the motor shaft. Part was precisely machined so that it could be heated, pressed onto the shaft, and then cooled.
http://evdrive.com/BMW_project/ACmotor.html

[Daox]

Finally at home so I can view the video. Very nice!

[gascort]

pretty cool. I was always curious how to do this. I agree with CaptainSlug, I would have expected a keyway ground into the spline off the clutch plate, but as long as the welds are strong enough, it doesn't matter!
Does the electric motor drag at all when you shut it off? I thought the EOC-ing would still be something you'd want to do if you could, and wouldn't that allow you to change gears? Of course, putting a clutch on that would be very hard.

[gascort]

Oh, and thanks for the video. We will look forward to future installments!