CasaDelGato - Images from the House of the Cat

Home > Electric Vehicle > Ford F250 EV Conversion > Motor Coupler 1

2008-04-18_15-28-44.JPG
Pulling the engine9193 viewsRemoving the 460cui gas engine. (Having a forklift really made this easier.)
All 762 pounds of it!
2008-12-31_13-59-48.JPG
Starting the 1st version of the Motor Coupler4168 viewsHere we are starting work on the first version of the coupler to connect the 2 Impulse 9" motors.
This is going to be a single piece coupler that press-fits on both shafts.
2008-12-31_18-08-00.JPG
Boring the hole in the motor coupler1907 viewsHere we are boring the hole for the motor shaft. 1/2 the hole has to be a larger diameter since it's coupling a tail shaft to a main shaft.
2009-01-02_20-17-50.JPG
Finishing the coupler1831 viewsHere we are putting the step in one end of the coupler so it can fit down into the end-bell of the motor.
2009-01-02_21-52-54.JPG
Finished Coupler2866 viewsThe finished coupler. (Well, I did have to have 2 keyways cut into it, and drill some holes for set screws after this.)
2009-02-14_12-53-28.JPG
Position motors8069 viewsMotors were mounted to the transmission, then lifted in from below.
Transmission was then bolted to it's mounts, and the motors placed on blocks to keep everything in position
2009-02-15_17-09-34.JPG
Building Motor Mounting Framework7207 viewsWe decided it was easiest to juts build the motor mounting framework in place. Carefully cut pieces and clamp them in place, then tack weld it all together.
2009-02-17_13-13-58.JPG
Completed Motor Mount5817 viewsThis is the motor mounting framework, after all the welding was complete.

2009-02-17_15-54-18.JPG
Painted Motor Mount6035 viewsI then sandblasted it all ,and painted it.
2009-02-21_13-48-38.JPG
Motors Installed6753 viewsEverything is in and bolted down. The framework is mounted to the original rubber engine mounts that used to support the 460cui Gas Engine.
2009-03-24_16-13-34.JPG
Battery Box Bottom8143 viewsThis is the bottom of the battery box. It is 3/4" plywood with a 2x2 edge frame.
The colored boxes are pieces of plywood cut to the size of Golf Cart batteries.
2009-03-24_16-15-18.JPG
7538 viewsThis shows how there will be 6 batteries across at the back. (there are 8 across at the front)
12 files on 1 page(s)