Thursday 23 June 2016

Back on.. Getting the motor mount parts made

Managed to find some time to get started on the motor mounting parts. A bit of a change of plan on ways to mount the motor to the gearbox, instead fo making a bespoke part from scratch I found that I could base the adapter on a standard disk brake as it was already the same shape. After looking around a bit I found a Suzuki Jimmy SUV front disk brake was the best fit, it has a 289mm OD and is 41mm deep, ideally it would have a 101.8 hole but it was 107 so I need to make a centering ring, but it's pretty close. I'm hoping the fact disk brakes are Iron/carbon is not going to be a problem, apart from being a bit heavy.

I've drilled it out to fit the gearbox, as I only have access to a mill without a readout the easiest way was to reference everything from a corner, this drawing shows the hole positions. 
So I now have the mount plate made, and all the holes seem to line up quite well. Turned a couple of locators to help with final alignment onto the gearbox

Also turned the shaft to spline adapter, although I've simplified it a bit when I turned it as I wasn't able to do the rotated arcs on the manual mill, but the parts seem to fit together well. 



So I've offered up the gearbox onto the motor with the parts and it looks ok, the thinner than originally planned disk based adapter does mean the end of the spline hits on the end of the motor shaft by 2mm but I'll cut off the end of the spline. Having the motor closer to the gearbox will be a big benefit to fitting the whole lot into the frame as there is very little space between the motor and frame.