I assembled my motor with insert coupler. One side has smooth shaft other has splines. http://www.diyelectriccar.com/forums/showpost.php?p=1001458&postcount=2047Trying to locate a splined hub to get a quote on a broach. Hang in there.
Oh... in that case i recommend you find a machinist that can make you a splined hub directly from those couplers. I find them very sturdy cast steel. It may also be tempered. File draw shows shiny steel surface.I follow what you did, but, I still need a splined hub. The particular car (s) that you referred to are simply not readily available in the USA. My Son is checking with inport car repair shops to see if anyone can offer a supply house to purchase a clutch disc.
Those ebay links you provided all have a 3 piece kit and shipping all that would be almost $400.00, just to get a splined hub piece. I was offered a CAD drawing file for nearly that much, but, I simply don't have that kind of money to take a chance on moving enough couplers to recover my expenses.
There is no telling what a broach will cost. A splined hub would get me way down the road to pricing out product. I was hoping someone in Europe would assist me with procuring and mailing a hub, since this forum is viewed world wide.
I assembled my motor with insert coupler. One side has smooth shaft other has splines. http://www.diyelectriccar.com/forums/showpost.php?p=1001458&postcount=2047
Main thing is i found bare lovejoy coupler pair with insert for some 60€. Then i cut out clutch hub with splines and made a seat in coupler. That way splines actually transfer torque without being welded. I wanted to avoid that so as not to weaken splines.
One could do the same for Leaf motor and transmission on the other side. This kind of joint can eat some missalignment and still be hardy enough.