Chevy Volt and Electric 3 series BMW (Ev-36/46)

Here is my flywheel adapter redesigned to use a 1610 taper-lock and Modified Taperlock sprocket. I plan to install the taper lock with the setscrews facing the motor so the clutch pressure will press the adapter on tigher instead of trying to pull it off. The other big change is since the center of the sprocket is larger dia then the pilot of the flywheel I plan to use 2 dowels to locate the flywheel on the adapter. (one is in the flywheel from the factory. I'll have to add the other). I also plan to put a bushing/spacer between the motor and taperlock so the clutch force can push the assy forward. Anyway I have attached a 3D screen shot and a drawing of the adapter for your review Parts below Purchased from McMaster Carr Taper-lock Bushing- Bore Steel Sprocket # 60: 2590K83 Taper-lock Bushing, Size 1610 1-1/8 bore: 57095k164 Aluminum Plate (6061) 5/8 x 12 x12": 8975K159

I also hooked it up to my battery charger and ran it for a few min. It was nice and quiet. Quite satisfying to see/hear it spinnig. While I was at it I stood it on end and set the trans on top of it to ensure I have my dimensions correct for my adapter plate thickness. Thick enough to keep the trans input shaft from bottoming out but not too thick to have it not engage the end of the motor shaft. Looks like 1.125 thick is going to work great. Here is a pic of my measuring set up. 2 pieces of angle bolted to the motor then some spacers (happen to be sockets in my case) of the right length.

Monday the Warp 9 motor arrived. Today my aluminum flywheel arrived. Parts are starting to roll in Here is the motor as delivered infront of my V-8 powered 3 series. Here is how it was packaged. Looked pretty safe and un harmed. Some initial inspection shows that someone at the factory ran a razer knife or something similar down the larger drive shaft like they were cutting a tag off it or something. Left a pretty good scratch but It can be buffed out. No pic of the flywheel yet. I did some reading and decided that a taper-lock hub is probably the way to go. So I have to redesign my flywheel to motor attachment. Back to the drawing board

Been awhile so time for an update. While waiting for the long lead time EV parts (controller and motor) I have been shoping for a donor car. Just about bought one last weekend. After realizing the only thing I needed it for was to remove the engine and make the motor adapter I choose to just buy a transmision instead. This way I don't have another whole car hanging about the place for months while I just wait for parts. Of course if the right donor car pops up I'll grab it but until then I have something to work with. So with that in mind I started working on a adapter to adapt the WarP 9 motor to the BMW flywheel. First thing I found was the JPG drawing of the warp 9 is pretty much illegible from the netgain site. Oh well I could make out what I needed. I'm plaining to make the adapter out of a sprocket with the ID bore and Keyway dimensions required to fit the motor. Will save on some machining. I sketched it up on paper but would rather have a cad drawing. I downloaded a...

I got notification that the motor will ship sometime in early October. Glad I'm not in a hurry because the controller will take even longer. Sadly I haven't even heard as much as boo from Cafe electric on a projected date. From what I gather from everyone else I should be expecting just in time for christmas

Well a little new news on the EV front. My powersteering pump arrived. Here's a picture for those that need a visual fix. The other big news is I ordered my motor today. Went with the WarP 9" as previously outlined. Been shoping for cars too. I really don't need the car until I get all the parts collected but if the perfect one was to pop up.... I've been looking at batteries. I'm thinking I need about 1,000 amp hrs worth.

I ordered a 2001 MR2 which from what I understand is less used by people for swaps. Cheaper and more available at the moment. Since I'm collecting parts and waiting for the zilla I have plenty of time to sort out the differences with the different style pump.