Zach’s Electric Diablo

I spent the day trying to figure out the best way to bolt my motor to the transmission. I need to make up about three inches. One option is to go buy a three inch thick piece of of aluminum and start machining. This would be expensive and take a lot of machine time. My other option is welding up a structure. My only concern with welding is the amount of heat deformation I would get. However, if I weld it, then stress relieve it, then fly cut the top and bottom surfaces, I should be good. We’ll see…

I also spent a little time making a clutch alignment tool and a test adapter plate out of wood to test the accuracy of a CAD file someone gave me.

Our flywheel is starting to look like the real deal.

It started out as a 2″ thick piece of 6061 and I roughed it out using a 1″endmill on the Haas. I also machined the alignment pocket and drilled the hole pattern to match the adapter hub.

Then cleaned it up on the lathe and added the pocket for the pilot bearing:

Here is the clearance “dish” for the clutch disk springs:

Then back on the CNC mill to drill the final hole pattern for the steel friction plate:

On top of all this progress on the flywheel, there is word that my axles are coming on Wednesday (YEAH!). Here’s to them being correct length…