oem hardware: adapter plates, couplers, axles, etc
Posted: Sat Oct 23, 2021 7:36 pm
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.
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.