This post is very delayed because it took long to set things in motion and we wanted to wait a little so that we could show a little more progress.
The last couple of weeks we have been working a lot on how we are going to mount the motor on the transmission. First we made contact with a local workshop and asked for advise. The workshop had worked on a electric car before so they could give us much relevant information. They also said that they could help us build the custom parts we needed. We started to make drawings and after that we went out searching for some metal.
What we need is a axle adapter between the motors axle and the transmissions axle. And we also need a adapter plate that holds the motor in place on the transmission.
At a junkyard we found this crazy big clump of metal that was perfect to use when we are going to make the adapter plate.
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| 400 mm diameter axle is perfect for us. |
We also found this old propeller axle that we are going for the axle adapter.
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100 mm diameter axle.
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We did not have a big enough lathe to do the initial processing on the adapter plate so we had to send it to a bigger workshop first. They where going to cut it down to 328 mm diameter and make a hole in the middle of it.
Here we have it before it was sent to the workshop for the processing.
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| 400 mm diameter and 50 mm thick |
While we waited for the adapter plate to be done we started to work on the cooling system.
We went to the car scrapyard and found a easy to dismantle and small size radiator. Simon started with checking if the heat sensor and fan motor was working.
Here you can see him boiling the sensor and testing at what temperature it outputs a signal.
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| It is switched on at 91°C and off at 86°C. |
Then he tested the motor and found that the system is working great.
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| He is heating the sensor with the heatgun and after awhile the motor started to spin. |
I have worked hard on trying to backwards engineer the controller we got. As you may know we did not get a manual for it and the company we got the controller from is now bankrupt. I got in touch with a exworker from the company and we have gotten a few question marks solved but i still have a few problems left.
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The controller
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After a while we got back the adapter plate and we sent it to our friends at the small workshop. So that they could make the final processing.
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| A shiny adapter plate |
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| The adapter plate next to the transmission. |
