CasaDelGato - Images from the House of the Cat

Home > Electric Vehicle > Ford F250 EV Conversion > Flywheel Mount

2008-04-18_15-28-44.JPG
Pulling the engine11358 viewsRemoving the 460cui gas engine. (Having a forklift really made this easier.)
All 762 pounds of it!
2009-01-07_11-11-18.JPG
Starting the Flywheel adapter3306 viewsThe flywheel adapter started as a big chunk of steel.
2009-01-07_12-58-42.JPG
Flywheel adapter work2531 viewsWe continue cutting
2009-01-07_13-25-26.JPG
Flywheel adapter work contd2302 viewsThe back of the adapter is almost done, getting ready to bore the hole.
2009-01-07_15-22-16.JPG
Flywheel adapter boring shaft hole2635 viewsWe start the boring process using a big drill bit.
2009-01-07_16-51-48.JPG
Flywheel adapter boring shaft hole contd2708 viewsAnd finish the hole using a boring bar
2009-01-08_13-32-18.JPG
Flywheel adapter - oops, hole too big2341 viewsWe didn't read the caliper quite correctly, and accidentally bored the mounting hole for the pilot bearing a bit too big. (20 thousandths or so)
So we brazed in some metal and had to re-do that hole.
2009-01-08_14-48-32.JPG
Flywheel adapter - finishing it up2540 viewsWe've cleaned up the pilot bearing hole, and are finishing the surface to the thickness needed.
2009-01-08_18-00-54.JPG
Flywheel adapter - finishing with the lathe2507 viewsFinished the lathe work, just needs drilling now.
2009-01-08_19-46-06.JPG
Flywheel adapter - drilling holes2613 viewsDrilling and tapping the holes to bolt it to the flywheel.
2009-01-13_19-52-46.JPG
Adapter Plate alignment2316 viewsI had a big aluminum plate made into a bell-housing adapter plate, and another big aluminum plate for the Impulse 9 motor.
In order to get everything lined up with the transmission shaft properly, we built an alignment tool.
It fit snugly into the hole in the bell housing where the transmission mounts, and was the same diameter as the centering ring on the motor.
2009-01-13_19-54-54.JPG
Adapter Plate alignment, contd2409 viewsHere the alignment tool has been pressed into the bell housing.
21 files on 2 page(s) 1