openinverter forum

gen1 (em67) and gen 2 leaf motor (EM57) shaft coupler

4149 chromoly steel


-designed to optionally mate with a 7208b angular contact bearing (removes any loads on the leaf motor shaft)


additional machining required

Adapter plate CAD :https://github.com/angusjo/leaf-splines ... ate.SLDPRT

When the bearing is utilized, mounting flywheels or drives shafts is possible.



260$ CAD + shipping



I hold no liability for any results occurred from the use of the coupler.


www.bratindustries.net

Id be interested in one, would have to be sent to UK.

Would you consider selling the CAD file only ?

Whats the plan on cutting the splines? EDM or broached?

slow67 wrote: ↑Mon Feb 24, 2020 8:06 pm Whats the plan on cutting the splines? EDM or broached?

Broached currently, still looking at edm services.

Cnc service is the most streamlined/best cost from what I’ve seen

BMW2002 wrote: ↑Mon Feb 24, 2020 7:53 pm Id be interested in one, would have to be sent to UK.

Would you consider selling the CAD file only ?

No problem there, some Cnc services I’ve looked at have a “drop shipping” like service. They would send u the part.

It’s open source, but this is about a group buy

Bratitude wrote: ↑Mon Feb 24, 2020 8:23 pm

slow67 wrote: ↑Mon Feb 24, 2020 8:06 pm Whats the plan on cutting the splines? EDM or broached?

Broached currently, still looking at edm services.

Cnc service is the most streamlined/best cost from what I’ve seen

Broached will likely be the cheapest in the long run (after the cost of the broach is overcome).

Im interested. I probably need a different bolt pattern but I can make it work. Maybe later I can make my own and have that shop broach it for me.

I'm in.

I'll be in if getting it to the UK isn't too expensive.

slow67 wrote: ↑Mon Feb 24, 2020 9:31 pm

Bratitude wrote: ↑Mon Feb 24, 2020 8:23 pm

slow67 wrote: ↑Mon Feb 24, 2020 8:06 pm Whats the plan on cutting the splines? EDM or broached?

Broached currently, still looking at edm services.

Cnc service is the most streamlined/best cost from what I’ve seen

Broached will likely be the cheapest in the long run (after the cost of the broach is overcome).

Im interested. I probably need a different bolt pattern but I can make it work. Maybe later I can make my own and have that shop broach it for me.

I’m thinking of leaving out the bolt pattern, so it’ll be blank. So what ever pattern anyone wants they can mill it after the fact.

Also making it compatible with a variety of 1 1/2 bearings so you can connect a flywheel or drive shaft.

Bratitude wrote: ↑Tue Feb 25, 2020 11:43 pm

slow67 wrote: ↑Mon Feb 24, 2020 9:31 pm

Bratitude wrote: ↑Mon Feb 24, 2020 8:23 pm

Broached currently, still looking at edm services.

Cnc service is the most streamlined/best cost from what I’ve seen

Broached will likely be the cheapest in the long run (after the cost of the broach is overcome).

Im interested. I probably need a different bolt pattern but I can make it work. Maybe later I can make my own and have that shop broach it for me.

I’m thinking of leaving out the bolt pattern, so it’ll be blank. So what ever pattern anyone wants they can mill it after the fact.

Also making it compatible with a variety of 1 1/2 bearings so you can connect a flywheel or drive shaft.

That's probably ideal. Any common machine shop should be able to do any desired pattern, but EDM or broaches are few and far between. Im in for one for sure with no bolt pattern on it.

How did you determine the profile of the splines?
I've got a Outlander rear motor here with a splined output and can't find anything that might fit the splined shaft.

Hi

Any update on a group buy, I was looking the 3DHUBS site, even just buying two pieces the price drops considerably.

There is a mass of build materials to chose from, would just steel be strong enough for the spline.

does your part need to threaded on the fixing holes,

Can someone link the rotex hub this is designed for ?

I'd be interested in one !

Can someone link the rotex hub this is designed for ?

Don't quote me , but I think it's a Rotex GS38.

zippy500 wrote: ↑Wed Mar 04, 2020 10:13 am Hi

Any update on a group buy, I was looking the 3DHUBS site, even just buying two pieces the price drops considerably.

There is a mass of build materials to chose from, would just steel be strong enough for the spline.

does your part need to threaded on the fixing holes,

Can someone link the rotex hub this is designed for ?

Yup. Almost done the design. Putting together a universal system, adapter plate, with a angler thruster bearing. Besides just direct coupling to a transmission, you could set up a fly wheel or drive shaft as well.

Working to keep costs low and increase use case.

I’ll have updates very soon and do a bulk order of the coupler.

Hi ,
Any news ?

purplespark wrote: ↑Tue Mar 24, 2020 11:27 pm Hi ,
Any news ?

Coupler and assembly design is now finished.
in a few days I’ll be sending out an order for 10 couplers, hopefully.
As I’m sure for many others here, life is a bit chaotic at the moment. So things are taking longer than usual.

Yes , of course , challenging times.
I shall wait patiently !

Mouse wrote: ↑Wed Feb 26, 2020 8:37 am How did you determine the profile of the splines?
I've got a Outlander rear motor here with a splined output and can't find anything that might fit the splined shaft.

Sorry to jump on to an old thread but did you find a solution to this? I think I have Meiden motor with the same 3/4in shaft as your Outlander motor. Been searching for something that fits and just starting to muck around in CAD to see what an adaptor might cost.

Bratitude wrote: ↑Wed Mar 25, 2020 4:06 am Coupler and assembly design is now finished.
in a few days I’ll be sending out an order for 10 couplers, hopefully.
As I’m sure for many others here, life is a bit chaotic at the moment. So things are taking longer than usual.

Hey, Bratitude,
Can you publish the finished design pictures?
I need to connect the leaf to a drive shaft.
I'm interested seeing if your design will work for me.
Thanks

Hi Bratitude

I am also running a Leaf motor and have gone the usual route trying out different clutch plates (Daihatsu, Volvo etc..) to no avail. I am interested in trying out your solution when it becomes available

The ghetto Leaf coupler is a Blue Print ADC43101 clutch disc or similar. It fits a bunch of japanese and korean vehicles and is cheap.

It's a loose match and probably different spline profile, but I've been running it for almost 30 000 km in my minivan so far just fine. There is enough meat in the splines. I assume the quite soft motor shaft will adjust to the very hard clutch profile over time.

If anything, at least it's taking a whole lot of time for anyone to be able to tell me "I told you so". 8)

jerrykco wrote: ↑Wed May 06, 2020 11:35 pm

Bratitude wrote: ↑Wed Mar 25, 2020 4:06 am Coupler and assembly design is now finished.
in a few days I’ll be sending out an order for 10 couplers, hopefully.
As I’m sure for many others here, life is a bit chaotic at the moment. So things are taking longer than usual.

Hey, Bratitude,
Can you publish the finished design pictures?
I need to connect the leaf to a drive shaft.
I'm interested seeing if your design will work for me.
Thanks

Currently away, but couplers are on order.

Ill try to dig out the specs. Spent a good amount of time setting the coupler up to be fairly universal for most people’s needs

What I currently access to.
was ether a 3in or 2.75 di plate with centring marks that match the rotex gs38 bolt pattern.

couple will nest in an angler bearing, with renting clip. For those wishing to run a clutch or drive shaft.

celeron55 wrote: ↑Fri May 08, 2020 4:46 pm The ghetto Leaf coupler is a Blue Print ADC43101 clutch disc or similar. It fits a bunch of japanese and korean vehicles and is cheap.

If anything, at least it's taking a whole lot of time for anyone to be able to tell me "I told you so". 8)

I smashed two blueprint Mazda center pieces couple of years back. It is not very hard too.
If I may suggest you put two center pieces in line and weld them in your coupler. That way it will definitely hold.

Torque is transfered along the shaft length...

celeron55 wrote: ↑Fri May 08, 2020 4:46 pm The ghetto Leaf coupler is a Blue Print ADC43101 clutch disc or similar. It fits a bunch of japanese and korean vehicles and is cheap.

Damien is using a Fiat Van clutch disc (watch from 2:35)

Kevin Sharpe wrote: ↑Sun May 10, 2020 8:38 am

celeron55 wrote: ↑Fri May 08, 2020 4:46 pm The ghetto Leaf coupler is a Blue Print ADC43101 clutch disc or similar. It fits a bunch of japanese and korean vehicles and is cheap.

Damien is using a Fiat Van clutch disc (watch from 2:35)

Is this the clutch plate?
Clutch Plate Fiat Ducato 2500 Turbo Diesel MK1 85-93 Clutch Disk?