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Nissan Leaf motor coupler

54253 Views 154 Replies 34 Participants Last post by  remy_martian
I want to go with pauls controller and leaf motor,


Has anyone found a Coupler that will fit the leaf output shaft?

I dont really want to spend £600 for the gearbox just to use the shaft out of it.

anyone ??

Thanks
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Thanks.

@Bratitude's drawing is great (it's his so I'll let him post it here), but it doesn't spec the spline info needed for the broaching tool.
So, has anybody figured out the Leaf motor spline's engineering specs yet so a proper coupling can be fabbed?
Yes, I have. The first batch of couplers is currently being made.
I’ve invested in the correct spline tool.
Outsourced the whole stuff.
Good news is that when I was at the company with a Leaf motor and matching spline piece from the Leaf gearbox they checked that fit and said “well, that will definitely improve.
I’m expecting the couplers to be ready in two weeks so by then I’ll know if it all works out.
I already have couplers available
2
Following up on this thread... after 4k miles on the Fiat clutch center pressed and welded into a coupler, I've had a failure. With about 1/2" engagement between the clutch center and leaf motor output shaft, the clutch center teeth have sheared.

I am having a new clutch center welded in such that I have about 1" engagement and hope that will last longer.

I suspect the welding i did may have undid any heat treatment the fiat part had. Either way, heat treating the coupler would have been a good idea.

To confirm, this Fiat clutch plate is a very good fit to the Leaf motor output. I just ordered 2 so I can replace the failed one and have another on hand.

I will try to post some images.

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the fiat clutch splines fit, but have the wrong pressure angle and diameter. also like you said, there isnt enough spline engagement. this is why i made couplers with the exact spline geometry and utilize the full length of splines. plus they are made from 4140 so stronger than any clutch spline material https://bratindustries.net/product/nissan-leaf-motor-coupler-2/
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Thanks Bratitude, I read through your page and it's very cool. Quite similar to my motor coupler but of course your splines are better!
Has anyone on here purchased this 'Online Gearbox Parts' adapter with coupler yet?




It seems perfect as long as the quality is good.

This adapter addresses the two biggest mechanical obstacles that I saw in using the Leaf motor. The first being finding or making a coupler (it is nice to see in this thread that there are a few options now), and the second is adding a support bearing. I always intended to fabricate a support bearing for the shaft/coupler because I would not trust running it unsupported in a custom application.
The 1310 flange coupler is also a dream come true since I planned to use the Leaf motor in a direct-drive configuration. However, it would not be too difficult to adapt a sprocket, pulley, or shaft to it. Not to mention there are all kinds of off-the-shelf adapters available for the 1310 flange.

If someone on here happens to own this adapter/coupler, please do share your thoughts on it.
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What is a 1310, a Dacia?
What spline does it use?
Perhaps it’s a match with one of the counter flanges for a flanged Leaf coupler I have coming up.

1310 is a standardized U-joint that a huge amount of RWD and 4WD driveshafts, differentials, and transmissions use. You can readily buy flange adapters for it to fit a wide variety of shafts, yokes, splines, etc.

For example, visit this website and type 1310 in the search box:
Perhaps it’s a match with one of the counter flanges for a flanged Leaf coupler I have coming up.
It would definitely be beneficial if you could use one of the common hole spacing patterns that these yokes use:

In fact, since yours has 8 holes, you could do dual patterns on it.
my couplers have a 40mm OD, made to fit a variety of bearings, as my original adapter plate system was developed for the exact option. i published the adapter plate files online for other to use.....which syncro gearbox just ripped off. a few people DM'd me saying they had similar things happen with synco gearbox.

anyways if you dont want to spend and arm and a leg https://bratindustries.net/product/nissan-leaf-motor-coupler-2/
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my couplers have a 40mm OD, made to fit a variety of bearings, as my original adapter plate system was developed for the exact option. i published the adapter plate files online for other to use.....which syncro gearbox just ripped off. a few people DM'd me saying they had similar things happen with synco gearbox.
Which is what engineers DO - if we did NOT do that we would still be worrying about which stones to throw at the sabertooths
i published the adapter plate files online for other to use.....which syncro gearbox just ripped off.
Was not aware of that. Sorry to hear it.

If you by chance have pictures of any support bearing setups using your adapter and coupler, I would love to see (not to rip off, I promise!).
My idea was to either mount a flanged bearing directly to the motor face, or mount the motor right behind the carrier bearing. Most RWD vehicles use two-piece driveshafts split at the carrier bearing. That way the carrier bearing would also act as a support bearing for the motor shaft.
Which is what engineers DO - if we did NOT do that we would still be worrying about which stones to throw at the sabertooths
Maybe, but when said engineer or business takes all the R&D risks, spends the time and buckets of money to measure and refine, it becomes a valuable property and its owner willingly shares it for personal use, sure.

When somebody abuses that permission for monetary gain, it's actual monetary theft. In the West, we call that "piracy". In China, they call you stupid for sharing it with someone that can build it cheaper (of course they can....no R&D cost both to recover and to do new stuff).

I learned early on in my biz career development (we engineers are largely ignorant of business practices -- engineers, usually on the spectrum, are just happy to work on cool shit and give away the farm ..."ooh, shiny plutonium - let's annihilate megacities with just one") that you cannot starve your suppliers. Do so, and the first on their accountants' chopping block is R&D.

Buy @Bratitude's couplers and you're giving him some cashflow to give us private users the next coupler, adapter plate, or gearset.

Buy one from an unauthorized pirate and the money may all go to hookers and blow (English slang for cocaine).

Now you know why I tagged him. Fuck the sabertooths when there's piratin' being done. He made it very clear his drawings were for personal use only. He shared it.

Somebody is making money and is not giving him his cut. He's not the kind of guy to demand it. Damned polite Canadians, eh
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Was not aware of that. Sorry to hear it.

If you by chance have pictures of any support bearing setups using your adapter and coupler, I would love to see (not to rip off, I promise!).
My idea was to either mount a flanged bearing directly to the motor face, or mount the motor right behind the carrier bearing. Most RWD vehicles use two-piece driveshafts split at the carrier bearing. That way the carrier bearing would also act as a support bearing for the motor shaft.
This makes my point. The pirates don't have the skills to engineer a reliable solution.

Who will you ask if @Bratitude throws in the towel on EV stuff and starts making napkin rings for wedding receptions?
Maybe, but when said engineer or business takes all the R&D risks, spends the time and buckets of money to measure and refine, it becomes a valuable property and its owner willingly shares it for personal use, sure.

When somebody abuses that permission for monetary gain, it's actual monetary theft. In the West, we call that "piracy". In China, they call you stupid for sharing it with someone that can build it cheaper (of course they can....no R&D cost both to recover and to do new stuff).

I learned early on in my biz career development (we engineers are largely ignorant of business practices -- engineers, usually on the spectrum, are just happy to work on cool shit and give away the farm ..."ooh, shiny plutonium - let's annihilate megacities with just one") that you cannot starve your suppliers. Do so, and the first on their accountants' chopping block is R&D.

Buy @Bratitude's couplers and you're giving him some cashflow to give us private users the next coupler, adapter plate, or gearset.

Buy one from an unauthorized pirate and the money may all go to hookers and blow (English slang for cocaine).

Now you know why I tagged him. Fuck the sabertooths when there's piratin' being done. He made it very clear his drawings were for personal use only. He shared it.

Somebody is making money and is not giving him his cut. He's not the kind of guy to demand it. Damned polite Canadians, eh
If you post it on the internet then you have given away any rights - no "theft" involved - No "Pirates"

and that is how most advances are spread (copying not the internet) - and have been for thousands of years

As far as actual "Patents" are concerned the USA is the last country that should complain as they stole EVERYBODIES patents for about 150 years
That's complete butthurt nonsense. Any prior art at the US patent office gets your patent application struck down.

The most innovative countries in the world have strong patent systems.

Posting on the internet with a noncommercial restriction on use is not at all what you offhandedly dismiss. It is enforceable, though it's recognized there's no honor among thieves.

And buying from thieves makes you one, in addition to being an ingrate for all the time and money someone spent to develop something that saves you several dozen, to hundreds of hours of your own time, risk, and money.

The US is not complaining. Canada isn't either - that's where the owner of the intellectual PROPERTY lives and relies on the decency of humanity.

Sadly for him, 5% of our society are psychopaths, amounting to 400 million "people", and they're the ones that say, "so sue me".

How much longer do you expect him to stay in business? To develop the new stuff @Matej suggests could benefit all of us?

You expect him to be intellectually cucked.

Just because you ran the powerdrill doesn't mean you get to pocket all the PROFITS.
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If you post it on the net you CANNOT patent it

And slavering about "not for profit" is about as useful as telling people they cannot paint it pink

If you don't patent it you have ZERO
There is NO such thing as "Intellectual Property" - its a misnomer - what there is is a short term (20 years) monopoly on that specific idea - and if you don't patent it......
You have a year from publication, yes even on the Internet, to file a patent.

US patents are a Constituionally guaranteed property right. Yes, it's limited to a 20 year ownership, but it is property for the validity period of the patent. Go ahead and call it a monopoly, which is what we like to hear it interpreted as.

The kind of posting we are talking about here is not patents, not property, but might be construed as a contract in a court of law. "In exchange for downloading this drawing you agree to only use this for personal use" How is that not a contract?

"so sue me, then" ?
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