[Jaesin]

Originally Posted by MalcolmB

I did a bit of reading about chain drives for my own conversion and one of the recommendations is to avoid using low tooth counts...

You are definitely right about that from all I have read as well. If I have a failure, I know for sure it is going to be because of that damn sprocket. Not only is it too small, the mounting for it is less than ideal but it is the biggest one that would fit inside the stock end plate. We will see what happens.


- Jaesin

[Jaesin]

I am designing a J1772 port for the mini that I plan to mill out of billet and I'm trying to decide on the cap style.

I wanted to see what you guys think between the Monza style and the typical rounded style flip caps.

I also have a design for a twist cap that has hidden hinges. It's a twist and flip design that looks like a regular round cap.

Opinions please!

Does anyone know the diameter of the port opening in the sheet metal?
I won't have access to measure mine for the next week or so.



- Jaesin

[Studebaker]

Here:




69.5 mm

[Joey]

Originally Posted by Jaesin

I am designing a J1772 port for the mini that I plan to mill out of billet and I'm trying to decide on the cap style.

I wanted to see what you guys think between the Monza style and the typical rounded style flip caps.

I also have a design for a twist cap that has hidden hinges. It's a twist and flip design that looks like a regular round cap.

Opinions please!
- Jaesin

I like the exposed ring of mounting bolts on the first option, but both look great.

[Woodsmith]

I personally prefer flush fitting with internal lock.
Prevents people being nosy about the fuel filler on and EV.

Otherwise I vote for the second one, no bolts.

[Jaesin]

Originally Posted by Studebaker

Here:

69.5 mm

Awesome! Thanks for that.

Originally Posted by Joey

I like the exposed ring of mounting bolts on the first option, but both look great.

Thanks for the feedback guys.

The mounting bolts are there in the first pic because that cap is on a motorbike. I think it looks great on the bike but it would start to take over on the rear of a mini. I'm was just trying to show the Monza style cap.


- Jaesin

[Woodsmith]

Originally Posted by Jaesin

The mounting bolts are there in the first pic because that cap is on a motorbike. I think it looks great on the bike but it would start to take over on the rear of a mini. I'm was just trying to show the Monza style cap.


- Jaesin

In which case Monza cap for me too. I just wasn't keen on the ring of bolts.

[Jaesin]

I decided to take the first motion shaft out and mill a proper keyway.

It's killed two solid carbide ALTIN coated end mills so far. Now I wait for new ones to get here from shars.

I cut the transmission end plate and bell housing in half because the chain and sprocket didn't fit in the top half of the end plate. I still need the lower half because it has the transmission mount attached to it. I will have to weld in some reinforcements for it.

-Jaesin

[Jaesin]

I got my new end mills from shars.com.

The 1/8th solid carbide ALTIN Stub length didn't have any problems cutting the shaft.

I have some clearance issues in the end plate I will work on tonight.


- Jaesin

[Jaesin]

The chain is attached but things are a bit tight. I will do a bit of milling on the case around the idler gear bearing to allow a bit more space for the chain to move around on the sprocket. Everything is looking good though. I have another spacer for the lower sprocket I can try that will allow the chain to back off the transmission end plate a bit.


-Jaesin