06-24-2008, 10:06 PM
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#1 (permalink)
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EV test pilot
Join Date: Jan 2008
Location: Oconomowoc, WI, USA
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Open Source electric conversion information
Hey everyone!
I am having a machinist build a transmission adapter plate for my Metro, so I can attach an electric motor to it.
Since the machining will be done on a computer controlled machine, why not save the information as a file which I can upload for other people to use?
Once I have my plate done, I am going to ask the machinist the save out the file for me as a .DXF file. Then I can post it for anyone else who wants to make a Metro adapter plate.
Granted, everyone is going to use a different motor, but the transmission information will still be good.
Maybe there is other information that we can freely share with each other to help make other people's conversions easier.
-Ben
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06-24-2008, 10:17 PM
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#2 (permalink)
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EcoModding Apprentice
Join Date: Jun 2008
Location: Waikele, Hawaii
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How much do you think everything will cost?
__________________
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06-24-2008, 10:26 PM
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#3 (permalink)
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EV test pilot
Join Date: Jan 2008
Location: Oconomowoc, WI, USA
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I am not sure how much the machining will cost.
The machinist is a super-nice guy. I have a feeling he will be giving me a really good deal.
I mentioned the idea to him of saving out a file to be able to share with other people, and he said it would be no problem.
He is a hot-rod guy, and I think he is just really excited to be working on an electric project.
I will be able to ask him how much time he put into it and at least be able to provide that time estimate to others. Or, better yet, save other people a lot of time by providing them with a file of "the shape" of a Geo Metro transmission housing.
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06-24-2008, 10:30 PM
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#4 (permalink)
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Batman Junior
Join Date: Nov 2007
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Great idea, Ben. FYI, our machinist charged us about half what we would have paid, had we not known the guy. And we paid about $250 for him to assemble our coupler (from supplied parts - machining and welding) and drill the precision holes in our supplied "blank" adapter plate.
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11-08-2008, 09:47 PM
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#5 (permalink)
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EV test pilot
Join Date: Jan 2008
Location: Oconomowoc, WI, USA
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Open-Source EV Geo Metro conversion
Hey everyone!
As my gift to the world, I am going "open-source" on my work on the Electro-Metro.
I recently had a request from a guy in Tasmania for the file that was used to make the adapter plate between my electric motor and transmission.
I was able to get that file today, although I do need to mention I did modify the plate after it was made.
I am uploading the file here, with the hopes that you good folks can help me modify the DXF file slightly, watermark it with both my web address and ecomodder.com, and give it to the world!
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11-08-2008, 10:00 PM
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#6 (permalink)
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EV test pilot
Join Date: Jan 2008
Location: Oconomowoc, WI, USA
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This file is able to be read by machining programs and many 3D design and animation programs.
In this file, the center circle and six holes around it are specific to the particular motor I used.
The outside holes and general shape of the plate are specific to the Geo Metro/Suzuki Swift 5-speed manual transmission.
Mine was from a '96 car. The second transmission I used was from an unknown year, but was exactly the same. I don't know if they ever made any changes to the transmission, and thus would need to mark this plate as for 19XX-19XX model years.
This drawing needs to be modified so that the concave notch (for the passenger-side wheel driveaxle) is about 3/8th inch bigger - that is to say that I later had to cut off about 3/8ths more later from the plate because there wasn't enough room to fit the axle back in when I tried to hook it all up in the car!
It would also be nice to mark the center of the inside circle on this drawing. The center of that circle is the location of the transmission driven shaft. That's good to know, because the tranny shaft is NOT centered in the transmission!!!
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11-08-2008, 10:45 PM
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#7 (permalink)
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EV test pilot
Join Date: Jan 2008
Location: Oconomowoc, WI, USA
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Here's a JPG version of that file so everyone who isn't into CAD or 3D can see it.
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11-08-2008, 11:18 PM
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#8 (permalink)
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Misanthropologist
Join Date: Sep 2008
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Here it is in Alibre Xpress Part file format (minus the bolt holes you added for your specific motor).
With Alibre Xpress you can open and edit it to add the hole pattern for your specific motor.
Mechanical 3D CAD for Everyone. Powerful. Easy. Affordable.
Here's how to take CAD drawings from Alibre or Autocad and turn them into printable machining templates.
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02-14-2009, 11:23 AM
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#9 (permalink)
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EV test pilot
Join Date: Jan 2008
Location: Oconomowoc, WI, USA
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OK - here is an updated image:
The round notch on the bottom left needs to be a little bigger for the passenger-side CV joint. Also, up isn't up. I marked in a red line showing the approximate direction of up. The red line on the right shows extra metal that could be trimmed off to make a little more room for long batteries in the radiator area.
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