Nissan leaf hardware: adapter plates, couplers, axles, etc

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Bratitude
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Nissan leaf hardware: adapter plates, couplers, axles, etc

Post by Bratitude »

The amount of development around open software (and electrical hardware) for a variety of oem parts is astounding!

But as the software side nears plug and play, I think hardware side should too.

I want to extend these efforts into the hardware realm:


-universal adapter plates
-gearbox stub shafts and flanges
-replacement gear sets
-motor couplers

Leaf parts are a favourite around here, and for good reason. cheap, powerful, and easily hack-able.
software side, driving leaf components is fairly flushed out, and nearly plug and play.

now on to hardware:
I'm mainly focused on leaf parts at the moment, but creating a repo of designs for a variety of gearboxes and motors would be ideal.




Adapter plates:


em57 adapter plate with NEMA B-face bolt pattern cad files: https://github.com/angusjo/adapter-plate

depending on the gearbox your adapting to, some additional backing spacing might be required, simply add some B-face patterned shims.

Im planing on machining a batch of these em57 adapter plates. Trying to hit a price of under 300$ cad each. If your interested, let me know.


Over time, building up a public repository of different gearbox bellhousing bolt patterns would really simplify and streamline the conversion process for many folks. If you know of any sources for gearbox bolt patterns, please let me know.





Gearbox stub shafts and flanges:

The leaf gearbox is a small, and strong gearbox. Though its not often it's utilized in conversions.
This for most part, appears to be the issue of cv axles.

me and janik have been discussing about cv stub flanges.
we've started developing a set of stub shafts flanges for the leaf gearbox.

they are going to be a 2 part assembly, this is to increase use case and reduce manufacturing cost.

1: the stub shaft has leaf splines on one end, and 25 spline Subaru on the other.
2: the flange will be a female 25 Subaru spline with a 108mm and 100mm cv joint bolt pattern.

vw type 2 use the 100mm and porsch 930 use 108mm style axle flanges. these bolt patterns are used on virtually all European vehicles. With plenty of material available to machine in custom patterns if required. flanges like these are already available from suppliers like http://www.subarugears.com/

The gearbox has a offset diff in relation to the motor, resulting in different leaf axle joint lengths, accompanied with a bearing support. for simplicity and cost, the bearing support and longer axle joint wont be utilized. One replacement stub shaft design will be used for both sides of the gearbox.



replacement gear set:

changing the 8:1(ish) reduction to something closer to 4:1 would allow the leaf gear box to be used as a replacement for transfer case in 4x4/awd vehicles.

this would require a change to the first and second reduction gears to a 1:1 ratio.
looks like 2 bespok replacement parts are needed: a new splined reduction gear, and a new input shaft with matting outer splines.
https://bratindustries.net/ leaf couplers + adapter plates
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Jack Bauer
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Re: Nissan leaf hardware: adapter plates, couplers, axles, etc

Post by Jack Bauer »

That's brilliant work!
I'm going to need a hacksaw
Robert
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Re: Nissan leaf hardware: adapter plates, couplers, axles, etc

Post by Robert »

Bratitude wrote: Sat Oct 23, 2021 7:36 pm replacement gear set:
changing the 8:1(ish) reduction to something closer to 4:1 would allow the leaf gear box to be used as a replacement for transfer case in 4x4/awd vehicles.

this would require a change to the first and second reduction gears to a 1:1 ratio.
looks like 2 bespok replacement parts are needed: a new splined reduction gear, and a new input shaft with matting outer splines.
While you're in there, can you design a spool to positively connect the "front" and "rear" driveshafts together?
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Bratitude
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Re: Nissan leaf hardware: adapter plates, couplers, axles, etc

Post by Bratitude »

Robert wrote: Wed Nov 24, 2021 4:10 am
While you're in there, can you design a spool to positively connect the "front" and "rear" driveshafts together?

Nismo makes LSDs for the leaf gearboxes already, but yes I would like to talk with quaife about a atb or a spool
https://bratindustries.net/ leaf couplers + adapter plates
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Tremelune
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Re: Nissan leaf hardware: adapter plates, couplers, axles, etc

Post by Tremelune »

Bratitude wrote: Wed Nov 24, 2021 1:26 pmNismo makes LSDs for the leaf gearboxes already
Interesting...Do you think this would help with straight-line acceleration? My Mini is FWD and it reeeally struggles to get torque to the ground from a stop.
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Re: Nissan leaf hardware: adapter plates, couplers, axles, etc

Post by Robert »

Tremelune wrote: Wed Nov 24, 2021 6:00 pm
Bratitude wrote: Wed Nov 24, 2021 1:26 pmNismo makes LSDs for the leaf gearboxes already
Interesting...Do you think this would help with straight-line acceleration? My Mini is FWD and it reeeally struggles to get torque to the ground from a stop.
The Nismo LSD is a helical gear type LSD. It would be great in your Mini but not for a rock crawler type setup. Torque sensing differentials require at least "some" resistance at both outputs and if you completely lose traction on one wheel (or one driveshaft in my example) you lose all your output power.

This link gives a good description of the issue

https://www.kmpdrivetrain.com/different ... ferential/
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Bratitude
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Re: Nissan leaf hardware: adapter plates, couplers, axles, etc

Post by Bratitude »

https://openinverter.org/wiki/Leaf_gear_box

Link to nismo lsd https://www.nismo.co.jp/products/nismo_ ... 19.html#a2


The trouble is ordering one from nismo Japan. I know it’s been done, but unsure how to get some for redistribution
https://bratindustries.net/ leaf couplers + adapter plates
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Bratitude
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Re: Nissan leaf hardware: adapter plates, couplers, axles, etc

Post by Bratitude »

some updates if any one is following:

Gen 2 leaf motor (em57) adapter plates with NEMA B-face bolt pattern are entering production!
Looks like I’m hitting cost targets bang on! they should be available for 330$ cad soon. Ye haw!

A coupler customer reached out and sent me a em57 gear box! So thank you for that!
then found a pair of clean axles for free!

So I’ve been busy taking measurements and doing to math for the involuted splines. Already into printed prototypes for the replacement stub shafts!

As janik found, the seals on ether side of the gearbox are different, but interchangeable (interns of fitment on the gearbox) so a seal swap on one side and stubs should be good to go.
A98DA529-C988-463D-B2B7-7972F81647F9.jpeg
image003.jpg
https://bratindustries.net/ leaf couplers + adapter plates
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Bratitude
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Re: Nissan leaf hardware: adapter plates, couplers, axles, etc

Post by Bratitude »

First mock up print of the stub flange assembly.
Just enough room!
tight between the flange and the motor, but ample room for a 108mm/930CV joint
8A5E1B8B-01B5-4375-898A-714378983364.jpeg
EB8027C0-26A8-400F-BC19-275D9B5BCD59.jpeg
https://bratindustries.net/ leaf couplers + adapter plates
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Bratitude
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Re: Nissan leaf hardware: adapter plates, couplers, axles, etc

Post by Bratitude »

updates:

-Machine shops are busy, and but things are trucking along. But the Gen2+ leaf motor adapter plates are coming soon.

-any one interested in some flanges for mounting hdt sprockets on the Hyundai HSG motors?

the shaft is 22mm diameter with a 4mm wooduff key. It’s non-standard keyway, so custom flanges are needed.

again looking at making something some what universal.
They would be machined potentially out of aluminum, and have a bushing style taper + bolt pattern to fit a variety of hdt sprockets
https://bratindustries.net/ leaf couplers + adapter plates
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Re: Nissan leaf hardware: adapter plates, couplers, axles, etc

Post by Bratitude »

em57 universal adapter plate drawing
0010-020-006_ADAPTERPLATE_11_27_2021.JPG
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Tremelune
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Re: Nissan leaf hardware: adapter plates, couplers, axles, etc

Post by Tremelune »

Well that's lovely. Has one been installed in a driving car yet?
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Bratitude
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Re: Nissan leaf hardware: adapter plates, couplers, axles, etc

Post by Bratitude »

Tremelune wrote: Sat Jan 08, 2022 2:50 am Well that's lovely. Has one been installed in a driving car yet?
Cheers.

not this revision with the NEMA B-face pattern, but the older design, which has the exact same mounting position for the leaf side, is in use in as variety of vehicles
https://bratindustries.net/ leaf couplers + adapter plates
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Bratitude
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Re: Nissan leaf hardware: adapter plates, couplers, axles, etc

Post by Bratitude »

finally leaf adapter plates are in. available in the web shop. https://bratindustries.net/product/em57-adapter-plate/
C1F10A98-6C64-4098-8B5F-7835A0E5D24A.jpeg

I’ve been working on the stub shafts for the gearbox. They have gone through quite a few iterations. Again around the goal of making them easy, inexpensive and universal. what I’ve landed on is a leaf-to-33 spline VW stub shaft.
560E34AA-6DB3-4109-AE43-C36F4F53BB62.jpeg
There are 3 different flanges available from many different suppliers for this vw spline: type 1(90mm), type 2/4 (100mm) and the 930 (108mm)

Using 930 flanges and joints will require shaving the motor casing, as they are just so big. even then, they might not fit.
E0C2DAF4-50F7-40EB-B312-3C6FAFC4762B.jpeg
the last final detail I’m working on is the seals. My original plan was to use the original leaf axle seal. this would result in a flange distance greater than what is on the original vw transaxle.
To Mitigate the odd flange spacing, the design could utilize the VW flange seal surface.
luckily there is a seal that fits both the leaf box and the vw flanges: OD 56mm and 36mm ID

using the flange seal surface will allow a tighter fitment, and will match the spacing of the flanges on a original vw trans axle.
https://bratindustries.net/ leaf couplers + adapter plates
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Re: Nissan leaf hardware: adapter plates, couplers, axles, etc

Post by Bratitude »

some updates;

stub shafts are in final phase. off to production soon!

adapter plate kits for old vw beetle/bus transmissions and nissan 5speeds.
intermediate bolt pattern is all nema b-face.
next is machine mockups, verify fitment, then off to production!
adapter-vwmock.png
adapter-71b.png
https://bratindustries.net/ leaf couplers + adapter plates
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Re: Nissan leaf hardware: adapter plates, couplers, axles, etc

Post by VWJoe »

Good work on the adapter plates, just checking a couple of bits on the VW plate. The two lower fixings on a VW gearbox are studs, is there enough clearance to allow for these. Also, the standard engine is not aligned by the bolts, but by a small lip on the engine ( now adapter plate) that goes into the bell housing. Is this present as I can not see it on the drawings. Hope this helps
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Re: Nissan leaf hardware: adapter plates, couplers, axles, etc

Post by Bratitude »

VWJoe wrote: Fri May 20, 2022 9:30 am the standard engine is not aligned by the bolts, but by a small lip on the engine ( now adapter plate) that goes into the bell housing.
Yup! That is present. The first screenshot shows a lip on the plate.
https://bratindustries.net/ leaf couplers + adapter plates
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Re: Nissan leaf hardware: adapter plates, couplers, axles, etc

Post by VWJoe »

Good to hear, hope the testing goes well.
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Re: Nissan leaf hardware: adapter plates, couplers, axles, etc

Post by motorcircus »

Any news on the Nissan leaf to VW axle stub adapters? Will they be available June or will I have to find another solution?
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Re: Nissan leaf hardware: adapter plates, couplers, axles, etc

Post by Bratitude »

motorcircus wrote: Fri May 27, 2022 10:03 am Any news on the Nissan leaf to VW axle stub adapters? Will they be available June or will I have to find another solution?
they are just entering the productions stages as we speak! no word yet on when ill have them, tho should not be long!
https://bratindustries.net/ leaf couplers + adapter plates
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