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Home > Electric Vehicle > Ford F250 EV Conversion > Assemble Motors 1

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Pulling the engine9163 viewsRemoving the 460cui gas engine. (Having a forklift really made this easier.)
All 762 pounds of it!
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Setting up to couple the motors3585 viewsThis is how we setup to couple the motors. Since both ends of the coupler are heated press-fit, once it's on. It's on. Forever.
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Putting coupler on 1st motor1949 viewsWe heated the coupler with a torch until it was VERY hot. Then we stil had to pound it down on the shaft.
Not a good sign.
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2nd motor 1623 viewsThen we quickly lowered the 2nd motor down into the coupler, and once again had to do some pounding.
Another bad sign.
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Cooling it all off2309 viewsCooling the coupler down to keep the bearings from getting cooked.
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Examining the result1525 viewsHere we are looking at the result, and finding that the motors had NOT pressed far enough into the coupler.
We had a 1/2" of extra space to deal with.
We were going to just add a 1/2" spacer, until we did some measuring, and found that the motors were NOT coupled straight. There was a definite wobble.
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Uncoupling the motors1749 viewsSo, we tried heating and prying to get the motors apart.
Nope, isn't going to work.
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Cut-em apart1684 viewsWe ended up cutting our pretty, brand-new home made with great effort, coupler apart with the cutting torch.
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Getting the coupler parts off2058 viewsThen we had to mount each of the motors in the lathe and cut the remaining parts of the coupler off the motor shafts. Being VERY careful to not nick or damage the motor shafts.
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Coupler almost off2467 viewsThis is the coupler when it's just about cut off.
We would cut down to the keyway in the coupler, then we could pry it open just enough to tap it off the shaft.
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Position motors8032 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
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Building Motor Mounting Framework7171 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.
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