[cricketo]

How about a bushing under the coupling ? I assume there is a shoulder on that shaft, so whatever you put in there should be seated against the shoulder. It seems like you've got enough engagement on the key, you just need to make sure the coupler doesn't shift towards the motor during operation. So basically you need a spacer. ID is known, OD can roughly match such of the coupler, and so the only thing you need to figure out is how much thickness you need for it.

 

[cricketo]

This is just connected to a hydraulic pump. Busted off the teeth. Do a search for Lovejoy here on this site. It is very much recommended to NOT use them in an EV.

There seems to be a grainy structure in the break - are they made by casting ?

 

[cricketo]

I'm not using a clutch for this conversion, so it's going to be clutch-less.

I think I'll go to the machine shop and see if they can give me a quote for welding the Lovejoy together with perfect alignment and a solid connection because I think that this may be the best option.

maybe I misunderstood the idea, but if you're welding the two halves together, isn't it easier just to machine a solid shaft coupler to begin with ?

To add, alignment on welded parts is never to machining tolerances. When a part is intended to be welded out of subcomponents, dimensions are left under/oversize to allow for finishing post-welding. So connecting two finished parts by welding is never a good idea.

 

[cricketo]

I agree with you here. If you are going to do a solid coupler buy one for that purpose.

if these couplers exist and don't require modifications, I would recommend to the OP to do the same - buy one. Custom fabrication, including machining, is rarely cheaper than a part produced in numbers. The only way to get one cheaper than that is to have a friend who can make it, but even then their time is still quite expensive just donated.

 

[cricketo]

I agree with that as well. I am asking how I can get one made. That's what my last post was asking. How can I get a solid coupler made? What do I need to provide the machine shop with so that they can make one? Please know that I am learning and I am very apt to change and persuasion because I am new to this. I have listened to what others have said which is why I am asking how I can do what is being recommended: get a solid coupler made specifically for my vehicle. Please let me know if you can help me answer this question and how I can get the job done right.

So others may be able to point you to an existing product. If you decide to have one made you have two choices - bring the parts that need to be mated to the machine shop, or sketch it up in CAD and bring them the drawing. If you draw it up in CAD you will be able to get quotes from shops that take orders online too.