Electric VW - Making the Coupling to join the motor to the transmission: Electric Car EVConversion
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- เผยแพร่เมื่อ 26 ก.ย. 2024
- www.drzzs.com
#DIYev #EVconversion
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I love this..the project, the way you filmed it...well done. My favorite quote was "There actually isn't a book that tells you how to do this". That is a sign though that you're working on only the best projects :D Hoping that you get this figured out, it'd be such an epic achievement!
thanks man. I'll use that as a way to measure all my projects. :)
This was very satisfying to watch!
What you did with that clutch and coupler was beautiful
I'm converting a modern beetle at the moment, just doing my coupler. I was doing some grinding near a wad of wire wool. Turns at that stuff is flammable :D
1st time ever commenting in your channel, all o can say is, right on my friend, love your eyeballs measurements and your way to do it. Keep the good work.
thanks!
It's good to see "production" videos and something alternate to Home Automation and LED's :).
You've done a great job doing the conversion on the bug. A lot of ideas went in that professionals often overlook.
Thanks!
Brilliant! Just starting my conversion tomorrow. Great timing. subscribed!
Way to go Doc! SPIN IT!
As soon as I saw you grinding I thought "Well, there goes the Leaf". As you found out with the windshield. You may also find the hood of your Leaf "rusting" in the next few years as the tiny hot metal fragments have embedded themselves into the clear coat. Get a clay bar and go over the entire front of the car.
Shoulda kept the sawzall blade oiled when cutting the motor shaft. The sparks mean shit's hot, and heat means soft. The blade is wearing fast because it's hot, and oil takes away heat (as smoke). Keep adding oil when it stops smoking, because that means the oil is gone.
If you want to cut the shafts correctly, spin the motor! Spin the motor while using a angle grinder, use a sharpie to mark it, and you barely have to do any work. EVwest has a video on this technique.
Besides the Acetone, the VW transaxles cases are made of magnesium alloy; so all the grinding sparks being produced around it does present the risk of (as Marvin the Martian would say) “an earth shattering kaboom”!
Oh geez. Now you tell me!
The right saw, for this job, is a lathe.
that's for sure! Then I could hollow out that motor shaft and lathe down the coupling the right way.
Dr Zzs cut a grove in the input shaft and place a circlip as a stop for your splined adaptor.
that's a good idea.
Did you get this motor running? The motor that you have is out of an E50XM2, it's a SEM (SEPARATELY EXCITED MOTOR) motor not a series wound motor. You'll need the appropriate type controller to run it. That's why the field cables were approximately 10 gauge and the armature cables were 2/0. The field runs on much lower current than the armature. Good luck with your project. You might go back to that yard and get the traction controller. The controllers have a pretty high failure rate so that might be why it's in the scrap yard in the first place.
It's good enough 😁
When 2 become 1 nice work
shoulda just popped down the local machine shop
Thing is doc, you make us more ignorant by making these videos! (still love them though :) )
I'm expanding your mind ;)
Great video but you shouldn't weld near the leaf, lol.
I love your engenuity, but I'm afraid this time you limited the transmission too much. In high torque situations like up hill under heavy load it will break. Also centering two shafts is very delicate for vibrations and alignment. Torsion will ruin it.
Why didn't you mount the motor from underneath ?
Thanks! You are very right. That coupling could break apart any time. I'm learning as I go here. I want to do more of these conversions. Hopefully I'll get better each time.
I tried every angle for getting the motor in there. From the top from the bottom, with the transmission attached or detached. What finally worked was (cutting it down), leaving the transmission loose but still in place so I could wiggle it some, then bringing the motor in from underneath. It was a major pain. Looking back, I wouldn't recommend anyone use a motor this size in a bug. There's just no good way to get it in there. A smaller motor would probably still push the car fine. I was just going for what was cheapest. $200 for that motor vs >$1000 for a newer/smaller one.
@@DrZzs Yeah you're right. I would do the same thing. Improvise with the stuff I have or can get cheap. It's a compromise worth trying. I thing the bug will run fine and maybe another motor opportunity may come along. Then you can swap them.
Looking forward to see the next episode.
It doens't matter that you're not an engineer. Me neither, I guess we're both 'arrangeers', it also ends on 'eer' so we're pretty close !
It' people like us that fix things and get the job done I guess ;-)
Wouldn't it have to be pretty balanced as well? High RPMs would have quite a bit of vibration.
@@TheOldBlackCrow Indeed. Especially certain oscillating frequencies cause problems. Avoid the RPM's that are causing the vibrations. No that easy in practise of course. For coupling shafts there are lots of solutions available on the internet. Adding rubber dampers is desirable, but in this setup there's not enough space. Unfortunately !
Love your vids man, especially the floating bald bliescreen head... make sure you wear ear plugs and goggles man! Sucks being deaf or metal in the eye balls! Keep it up
I am also working on E conversation
Doc, I am waiting to see you center the two hubs !
It's as close as I could get it with my caveman tools. They're pretty close to centered, but not very balanced. But so far it hasn't blown apart!
Love your DIY approach to this, that's exactly what us do. I hope that coupling lasts! Do you have to get the vehicle inspected and certified to legally drive it on public roads? We do here in Oz, and its not easy
I haven't tried to get it registered yet. I'm pretty sure with a car this old I can just register it as a historic vehicle. I'm pretty sure the safety standards are lower for historic cars.
Normally the elec controller would vary motor speed without transmission. Does using the variable speed elect motor and transmission feel ok, what vehicle speeds are you getting?
What are you using for batteries?
I want to do the conversion you've done with a 4WD dune buggy. Watching you makes me think it's possible. Not because of the DIY methods but because you did a great job showing your obstacles and solutions.- Thank you !
2:30 this is not OSHA approved 😂😂 but great fun video
That will shake and shake and shake while you increase revolutions, so, go to a machine shop, they will create that part with the same size but perfect balance instead. !!
Good luck to the motor and transmission bearings ! You'll be both missed ! 😂
Also good luck to the teeth on both shafts ! You'll live short but intense ! 😇
It's drives. That was my primary goal. Longevity is WAY down the list. :)
12:52. Looks like a 3D printed from a gone wrong CAD model. But hey, if it works that's all that matters. :) Im pretty sure that will be soon a smart car running in a HA software. Lol
you know it!
hmmm, grinding next to that Leaf ?, not a good idea...
When is the next video coming? I'm in the process of building an ev beetle myself and use these videos as research for it 😁
Get that porta band.
heck ya!
darn it you beat me by one login !
hehe
Hi Sir
I'd just use an appropriately sized pipe as a spacer
One of many expensive mistakes I've made.
Not quite sure that welded thingy is sufficiently balanced at speed, but hey, hoping for ya :)
I'm sure it isn't. We'll see how long it lasts :)
Take off the real wheel axle transmition slap on the motor and bolt back
Hi with the signifiantly reduced spline shaft length will you have enough float to account for movement in the transmission and motor assuming its going to be mounted on some flexible mount?
How to connect you
lol do you reallize that motor most likely has more torque then a v8 engine off the line. i would not have removed any i would have move trans or cut or beat the sheet metal to make it fit. we did a 95 chevy cavalier was a 5 speed and used all electronics and motor from a clark fork lift we did the same as you did but turned the stuff on the lathe so it was centered right and it was tig welded and the 1st ride he hit pedel to fast and it striped the spline right out of clutch side we had to doubble up that side or it ripe them out. best i can say is good luck and be easy on the go pedal are motor was a little bigger but not much.
BW reese is first!
Hyper drive for light speed😂
Obvious that you don't have much experience with machines. I like your style though.
Be careful using the VW logo in your video. They are very protective of their logos so much they have sued and won against 3rd party mechanics that had their logo on the wall of the shop.
ooh, good to know. thanks
See
Call me if possible Sir
You butchered that dude why didn't you just loosen the transmission in drop it down and made them up and then push it back into place
Please REMOVE YOUR CAR TO OUT SIDE, YOUR NOT EXPLOSION PROOF !
This is awesome! Step by step and you'll have the Tesla v2.0! But this is way better, self made puppy! Cheers!
Did you stop this electric beetle conversion series? Your playlist has a lot of other videos in it
How thick was your adapter plate?
It's called a hack saw...old but good
Might need to get that coupling balanced to avoid vibrations ripping things apart, but I'm guessing you did in the future.
ya, I'll probably have to do that eventually.
Perhaps I missed the episode where you answered this, but why not a direct drive with a smaller diff?
I thought of that when I couldn't get it to fit. I just don't know where I would find a differential to substitute for the original. Do you have some ideas?