[crazybry79]

EQUALS


I called Jims Golf Carts the tother day, and inquired about used golf cart batteries. After a short trip to Reedsville, we aquired out(4) T1275 Trojan deep cycle batteries.

[crazybry79]

First off, I owe a great big THANK YOU!!! to Brian at Klink Equipment, in Freedom.

With his help, I have aquired my EV100 controller. Plus, I aquired a potbox. PLUS, I aquired some misc switches, and other doo dads.Basically, I got everything in the engine bay of this old forklift, who gladly gave it's life for my cause.....


PLUS, I aquired not one, but TWO motors!!!

[crazybry79]

As you can see, there is a gear set on this motor, the one I planned (and still do) on using.






The gear set is actually in two peices. The out gear slops back and forth a bit. The inner most gear is secured. The shaft of this motor is splined, but externally. So I am thinking that I will permenently couple (via welder) the two gear sets, the attach the splined portion of the clutch plate to the gearset, and viola!!! Instant coupler! I am going to have to arrange to have a machine shop to this, so it is pefectly alligned.


I pulled the pump motor as well. But that has the dreaded internal splines. I also saved the pump, so I could save the input shaft, and hopefully utilize this motor as well.




The pump motor has got some advanced brushes too! Only two power inputs...

[crazybry79]

I didn't take a single note to where everything goes, though......
I did, however take lots and lots of pictures! One for each wire, to be exact!


If you would like to see the rest, they can be found here...
http://s94.photobucket.com/albums/l8...ile%20Uploads/



Here's the motor plate for the motor I'm using.



I did also get the adaptor plate cut.....but right now its so far from pretty, its not even picture worthy!!! Lack of patients and a plasma cutter is not a good thing!

[crazybry79]

One of my most daunting tasks was the coupler. I was not sure on exactly how to make it, and didn't know 100% how to procede. Well thanx to this forum, and one member especially, it consisted of about 5 minutes of work.

First, I started with the gearset.


I bought a "hub" from Tractor Supply Company. The hub actually fit a touch loose. So, on the smooth end of the gears, I wrapped masking tape around. I cut the tape so that it didnt overlap where the ends meet (to keep things perfectly true) and slid the hub onto the gearset. I did the same with the clutch hub. I put everything in the vice (clamped so that the whole assembly was pressed together - this prevented warpage when the first welds were applied), and did a bit of welding.....


Viola!


Even got the motor in! Now the only question was......HOW do i get my foot from between the axle and the motor!!!!


Now I need to figure out how to make a spacer that goes between the motor and adaptor plate (right now the output shaft of the motor and the input shaft of the trans are tight up against each other.....

Not to worry - the motor is sitting on a jack....

[billhac]

Originally Posted by crazybry79

One of my most daunting tasks was the coupler. I was not sure on exactly how to make it, and didn't know 100% how to procede. Well thanx to this forum, and one member especially, it consisted of about 5 minutes of work.

First, I started with the gearset.


I bought a "hub" from Tractor Supply Company. The hub actually fit a touch loose. So, on the smooth end of the gears, I wrapped masking tape around. I cut the tape so that it didnt overlap where the ends meet (to keep things perfectly true) and slid the hub onto the gearset. I did the same with the clutch hub. I put everything in the vice (clamped so that the whole assembly was pressed together - this prevented warpage when the first welds were applied), and did a bit of welding.....


Viola!


Even got the motor in! Now the only question was......HOW do i get my foot from between the axle and the motor!!!!


Now I need to figure out how to make a spacer that goes between the motor and adaptor plate (right now the output shaft of the motor and the input shaft of the trans are tight up against each other.....

Not to worry - the motor is sitting on a jack....

here is how I did mine, First I used 1/4" steel plate it was 3 foot square, then I I put the bell housing of the tranny, ontop of it and traced the edges with a sharpie, I marked the bolt holes, On some i could just stick the sharpie through and mark it but on some I made a reference mark and used my tape measure to find the center to drill. then i cut the edges that i traced and drilled all the bolt holes, then i measures from the bottom of the tranny to the center of the shaft and drilled a 3" hole with my hole saw. then I measured the motor mine was 7' round so it cut a 10 square piece of steel and drilled a 3" hole in it, centered it on the motor, and marked and drilled the bolt holes. now I bolted the tranny plate to the tranny, and the motor plate to the motor and put them together with the coupler, then measured the space between the 2 plates and cut some steel to fit between them, and welded then together, whola adaptor plate, looks like this, the square pieces with the bolts going through them are just to hold the 2 plates together for welding and can be removed before bolting to the tranny, but i skipped that step.

[crazybry79]

OK, copied your idea, kinda.

I took three peices of 1x2 and flipped them sideways. Drilled holes for the bolts to run through, and sandwiched them between the motor and adapter plate.






IT'S IN!!! IT'S IN!!!! (irony was, a song was playing as I bolted it up....("Nothings gonna stop us now"~~~)

[vpoppv]

Nice! You sure work quickly! You'll be needing video now so we can see a wheel moving from electric power!!

[billhac]

now you need to make a support for the end of the motor, dont just rely on the tranny for support. but it looks good.

[crazybry79]

Originally Posted by billhac

now you need to make a support for the end of the motor, dont just rely on the tranny for support. but it looks good.

I intend on making a bracket that goes from the original motor mount on the passenger side, that extends down to the adapter plate extentions. Unfortunatly, there is nothing to directly bolt to the end of the motor. With nothing on the motor, the whole assembly sags dangerously low, and exerts alot of force on the two remaining motor mounts.