Coupler Guidance

[maiks]

Hello,

I've designed a coupler that directly connects the Nissan Leaf EM57 motor to my gearbox. However, I'm facing a challenge: the coupler pushes too far into the gearbox, which ends up damaging (or "eating into") the aluminum section and causes the motor side to decouple.

I've attached images showing the affected areas.

After doing some research online, I found mixed opinions — some people recommend adding a stopper at the gearbox, while others don’t seem to use one at all, which has left me a bit confused.

I've ordered an upgraded coupler from BratIndustries (https://bratindustries.net/product/niss ... r-coupler/) and expect it to arrive soon.

[zippy500]

I followed what Damien did in one off his videos, just simply put some tack welds on the splines as a stop, although I'm yet to test it out

[maiks]

I followed what Damien did in one off his videos, just simply put some tack welds on the splines as a stop, although I'm yet to test it out

A friend tried it, but it makes noise whenever the coupler comes into contact with the welds, especially when driving at low speeds (around 30 km/h)

[Bratitude]

Loctite 660

[Alibro]

When making my coupler I used two clutch plate centres with one inside the steel tube and one on the end. The one inside was rotated against the splines and welded through a hole on the side of the tube. This way there is no slop and no clunk when going from forward to reverse or using regen.
It may not be as neat as the Brat Industries coupler but has worked trouble free for the last 5000 miles for me.
I can't remember how I prevented the coupler from moving up and down the splines but so far it hasn't been an issue.

[maiks]

Loctite 660

How am l supposed to apply it , l request for guidance on this

[zippy500]

Loctite 660

Must be good stuff, have seen the price of it.

[Slimjimmy]

Drill a hole for a set screw? Or press a bearing on the spline and use a spring to keep constant tension on the coupler which i imagine is free floating between both splined shafts