[JRP3]

Wondering how you are going to lock the coupler to one of the shafts?

[paker]

If the adapter for the motor to transmission is the correct width, as well as the coupler there shouldn't be a need for a coupler lock if there is no play on the shafts.

[JRP3]

Unless the coupler presses against the face of the motor and the transmission, which it shouldn't, there is nothing to keep it from constantly sliding back and forth along the splines, increasing wear and possibly causing vibrations.

[david85]

Originally Posted by JRP3

Unless the coupler presses against the face of the motor and the transmission, which it shouldn't, there is nothing to keep it from constantly sliding back and forth along the splines, increasing wear and possibly causing vibrations.

I was wondering if some one would catch that. You are correct. However, the wield actually shrunk the spline coupler for the transmission down to the point where some gentle hammering is needed to get it on the shaft. We are going to run it like that and see if it stays put. If if moves during normal use, we will drill and tap for a lock screw to hold it to the motor shaft. As it sits in there right now, its not possible for it to come off and disable the vehicle.

Getting ready to do a dry run of the motor and tranny in the car. Its sitting in there right now, but CV shafts still have to be installed and for that the wheel hubs still have to come off. Hope to have the mounts figured out for the motor tomorrow and finalize the adjustments of everything to make sure the shafts are strait and the motor/transmission is positioned where it should be. The motor is big, but theres still a decent amount of room around it. It fits like it was meant to be

Also, since this controller has a low voltage cut off, I will have to assemble the complete battery pack right next to the car for the dry run.

More pictures tomorrow.

[JRP3]

Originally Posted by david85

I was wondering if some one would catch that. You are correct. However, the wield actually shrunk the spline coupler for the transmission down to the point where some gentle hammering is needed to get it on the shaft.

Interesting. I was wondering if it would be possible, (don't see why not), to have the coupler spline machined for a slight press fit, which you seemed to have achieved inadvertently.
Slightly off topic, but I keep wondering if "wield" is some sort of alternate Canadian spelling of "weld"? I've never seen it used that way before.

[paker]

Originally Posted by JRP3

Unless the coupler presses against the face of the motor and the transmission, which it shouldn't, there is nothing to keep it from constantly sliding back and forth along the splines, increasing wear and possibly causing vibrations.

That's why one needs to find a competent machinist.

[Woodsmith]

Would the application of thread lock to one set of splines work?

[david85]

Yeah, thats how we spell weld up here. Every version of english is effed up in its own way (canadian, british, aussie, etc). Here we have the french influence on the language, but its not france french, its quebec french and yes there is a difference. I'm supposed to spell the word color as colour program as programme and so on. I tend to generally stick to american english though since all the extra letters in some canadian spelling seem completely pointless to me. Even then spelling of english tends to follow no real rhyme or reason. Some where in canada an english proffessor won't be able to sleep tonight and he'll have no idea why after I say that Silent letters really piss me off. I could rant all day about english lol.

I really need to learn a second language.

The idea of a lock screw would involve drilling part way into the shaft itself. Say, about a quarter of an inch or less and not tightening the lock screw all the way down inside the hole. Since there is some small amount of slack on the larger spline coupling, I don't want to tighten it to one side. Unlike keyed couplings, spline couplings tend to self center when under torque load. So what I had in mind was to carve the lock screw to 45 degree point, then tighten it to where it enters the drilled bore in the side of the spline shaft, but not enough for it to bottom out. That would locate the coupling, but still allow for some float without putting load on the screw stem. The lock screw would then require locktite since it wouldn't have any real torque on it applied.

Hope I explained that clearly enough. Basically thats my "plan B" should the coupler decide to start moving around.

[JRP3]

Originally Posted by paker

That's why one needs to find a competent machinist.

I'd think this is more an issue of proper design. Basically as long as the coupler is locked to one of the shafts you should be ok, but just having 2 splines, even well machined, may not be enough, unless there is a press fit on one, as in Davids situation.

[JRP3]

Originally Posted by Woodsmith

Would the application of thread lock to one set of splines work?

I don't think so if it's a slip fit. The only thing a thread locker prevents is vibration rotating a fastener. It might help in a light press fit situation, but I don't really know.