7 Build Your Own Electric Car: Adapter Plate

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Күн бұрын

300MPG.org
In this section, we cover how to build an adapter plate to mount the electric motor to the bell-housing of the transmission.
For some great ideas on different vehicles converted to electric, check out the listing at the EV Album! www.evalbum.com
This video is one segment of an instructional video I created in 2010 from a home-built electric car I made in 2008. Of course, battery and motor technology has advanced quickly since then, and affordable, commercially-built, Electric Vehicles are now a reality.
This video series covers ONE low-tech and simple way of converting a car to electric. Many of these same ideas and techniques still apply to go-karts, motorcycles, boats, and lots of other projects. We hope that you enjoy watching these videos and learn a little something from them.
A simple electric car conversion project like this one uses
A 0-5k ohm potentiometer throttle: amzn.to/2PwMmoD
A motor controller up to 144V: amzn.to/394QyUh
A DC Series-Wound motor (9-inch diameter typical): amzn.to/2TlqYUv
Battery Charger to match your pack voltage: amzn.to/2Toe0Fl
On this car, we used a simple power inlet: amzn.to/3abNWnI
But that also meant we needed to design a separate circuit to disable the ability to drive while plugged-in. That's a built in feature of the now standard J1772 connection used in modern commercially-built cars.
J1772 Inlet: www.aliexpress.com/item/40000...
You would then pair that with a standard J1772 EVSE: amzn.to/387ixRW
I show the internal connections you need for the J1772 communications at: 300mpg.org/2015/03/31/the-diy...
There are still a few copies of the original DVD for sale. Besides the video, the set also has a DVD-ROM with photos, web clips, and documents from the project.
All profits support our work and go towards future DIY Clean Transportation and Renewable Energy Projects.
300mpg.org/electric-car-instru...
You might also want to check out the book BUILD YOUR OWN ELECTRIC VEHICLE, by Seth Leitman and Bob Brant: amzn.to/2jFUXVJ
For CURRENT electric vehicle, DIY, and renewable energy projects, please visit 300MPG.org.
Music Credit:
"B-Roll" Kevin MacLeod (incompetech.com)
Licensed under Creative Commons: By Attribution 3.0 License
creativecommons.org/licenses/b...
We are a participant in the Amazon Services LLC Associates Program, an affiliate advertising program designed to provide a means for us to earn fees by linking to Amazon.com and affiliated sites.

Пікірлер: 63

@BenjaminNelsonX 5 жыл бұрын

We are now on Patreon! We'd love your support as it helps us produce more videos like this! www.patreon.com/300MPG

@Initial-B 6 жыл бұрын

I love the title, "machinist and hot-rod guy" lol. I'd love to tackle a project like this one day.

@terryi8892 5 жыл бұрын

Thanks I've watched some of your stuff and it a nice intro to electric cars for me

@gabsinthsky 6 жыл бұрын

Very clear, thanks!

@DaleESkywalker 6 жыл бұрын

Small tip on the shaft centering: Use a socket or a socket (that fits snug enough to not fall off-center, but not get stuck on the shaft) and extension if your shaft is more than a couple inches in. That way your cardboard doesn't get distorted... You can also check measurements from the outside where there's are points of reference ie holes, marks, etc.

@BenjaminNelsonX 6 жыл бұрын

Good tip!

@bcp092980 5 жыл бұрын

You could also extend the shaft until it is flush with the surface that you'll be mounting the adapter plate. Then use some washable ink to make an exact template. This will eliminate any measuring.

@JasonBlack66 6 жыл бұрын

3:00 or you could put a dob of paint on the tip of the shaft before you turn her upside down.

@JohnSmith-wo5gl 5 жыл бұрын

I'm thinking that the input shaft on the xmition needs to be right on or the gears will mesh wrong and totally lunch the gears.

@michaelbabatunde3915 5 жыл бұрын

Very good

@shawng5799 5 жыл бұрын

When I have made adaptor plates in the past for fitting bigger engines in smaller cars I use mild steel as you can gas cut it yourself and drill and tap the holes safely. You usually end up with so little metal left its not worth the weight saving of aluminium. Plus get a hole wrong and you can weld it up and have another go.

@dhcp1rx18 5 жыл бұрын

thank you

@donaldfaulk8992 5 жыл бұрын

Another idea is trace the trans directly to the adaptor plate and make one cut instead two (minus cutting the cardboard). more accurate. I've done this enough times to know. the center hole for the shaft can be larger for centering the motor.

@gurqhan 3 жыл бұрын

cool tip, any idea to center shafts of the trans & ev engine then?

@sevenskytamil82 5 жыл бұрын

Now a days we have to use in front moving diesel or petrol .back moving ev also we can charging battery by extra dinamo .I think like this . thank you.

@jarikinnunen1718 3 жыл бұрын

It is possible to make an adjustable adapter plate. Make larger holes than the bolts require. Using a large washer, it is adjustable. When the transmission is in line with the motor, attach it to the washers to the plate by welding. When it rotates without vibration, it is in line.

@elbertwilhite7458 5 жыл бұрын

Thanks

@ASTROMURTHY 5 жыл бұрын

Indian Govt should ease all Govt curbs and allow free hand to fix EV kits to all model

@ChrisHarmon1 6 жыл бұрын

Easiet way for someone to do the adapter 100% themself would be to take a picture of the transmission mount and motor mount then move the pictures into Fusion 360(free CAD program) and use Fusion to trace the outline, holes and trans input shaft. You would then need a rough measurement for distance of say any two bolt holes and scale your 2D outline to match your physical measurement which you could then print on piece(s) of paper to test the dimensional accuracy of your 2D drawing. From there do the same for the motor and this will allow you to easily print and test fit while making adjustments to the motors alignment accuracy repeatedly for just a few dollars tops, assuming you had to use a local print store. Best part is you simply extrude the drawing to the thickness of the plate you want and you now have a 3D rendering of the plate. Now with a $150 3D printer you could easily add dovetails and print the plate in pieces(# of pieces depends on 3D printers bed size) and glue them together to use for final test fitment and then as a template for drilling the holes.

@BenjaminNelsonX 6 жыл бұрын

"Easiest" is different for one person than another! However, if a person has skills with software like Fusion 360, go for it! I'm slowly working on my own vector/vinyl-cutting/laser-cutting skills.

@deathincarnatesplace 5 жыл бұрын

hey try a dual sided front wheel drive transmission but you will have to invent it. then put an electric motor on one side running on a scooter motor powered electric generator and a regular gas motor on the front side. but you know they will make it not work right but no one has invented the easily change out parts system yet that lets you get away with it. just make every piece as easy to install as a starter. this is to include the system for running and starting a scooter motor. then use them in a store bought product so that it is so easy to fix anything that breaking becomes obsolete. also you must do this for the regular gas engine. just make a super cheap version of meta breakable parts. which include but are not limited too starter, fuel injection control computer, points and spark plugs and alternator and fuse box. when someone comes up with cheap replacement parts eventually they will lose control. a timing computer can be replaced with a cellphone if it not kept in the engine compartment and is removed from its case to a much larger case with no cooling issues. don't use the phone plug it into the cigarette lighter plug but use the cheapest stuff in the world. heat sink tape may be an option for a 4 or 8 core used phones to seal for moisture while making it cheap to repair. 1 to 4 rear wheel scooter motors to 6 plug generator at 1 mile per hour test and if you say build it yourself again how about giving me the money to do so and i will.

@pudseybear9910 6 жыл бұрын

surely to mark out for the motor, you would jsut need to measure the diameter/radius and use a compass to draw the circle, assuming it was round of course, but most motors are, and would save dismantling it.

@BenjaminNelsonX 6 жыл бұрын

One problem with assumptions is just that they aren't always right! Certainly, a person could do some accurate work with a compass and measurements, etc, but it really is very easy just to TRACE the part. The drive shaft of the motor and the driven shaft of the transmission do need to be aligned very accurately. I made the assumption that the driven shaft of the transmission is in the center of the bell-housing. It isn't. On the first attempt of test-fitting all the components, we found that out. Always try to avoid assumptions.

@stuartx1000 5 жыл бұрын

I have enjoyed all your videos and perhaps, however, I probably missed a question that you already have answered? Sorry that the question so basic, but here goes: Since most motorized tools have a control that permits the unit to start at 0 rpm and go its max rpm, why do you need a gearbox as opposed to a sprocket of the appropriate gearing?

@BenjaminNelsonX 5 жыл бұрын

The short answer is that a sprocket of appropriate gearing would be just fine, for a more basic vehicle. When I built an electric motorcycle, that's all I did was connect the motor to the rear wheel with a chain and appropriate sprockets. The longer answer is that a car is more complicated than a motorcycle. Most commercially-built electric cars use an electric motor which can handle a wide range of RPMs. The motor is connected to a single-speed gear reduction, often up to a 10:1 ratio. After that, it goes through a differential to split the power to two drive wheels. In the case of a DIY home conversion of a vehicle to electric, you still need a place to mount the motor and a way to connect it to the driveline, a way to have gear reduction, and a way to split the power between two drive wheels. In a common front-wheel drive car, an existing manual transmission provides all those. (Even if you just left it in a single gear.) It would be difficult to connect an electric motor to a car with only a chain and sprocket. A transmission COULD be replaced with a dedicated single-speed gear reduction/differential combination. Right now in 2018, we're just seeing those types of devices coming to market for hobbyists.

@ledjohnnyboy 6 жыл бұрын

Hi Ben, I was how you supported the motor. Is bolting the motor to the transmission via the adapter plate enough? I'm concerned about the torque that the motor would exert on the transmission (80 lb motor).

@BenjaminNelsonX 6 жыл бұрын

In the original engine setup, there are three mounting points between the combination engine/transmission and the frame/body of the car. Two of those mounts were on the transmission and were still used. I reused the engine mount, but cut it and made a custom plate that connected to the back end of the motor. When done, all three engine mounts were reused, with just the one modified to support the electric motor instead of the engine.

@BenjaminNelsonX 6 жыл бұрын

Hi John, I'm going to make a follow-up video talking about exactly what I did to build a mounting bracket for the motor.

@ledjohnnyboy 6 жыл бұрын

Thanks Ben! Your videos are very informative and helpful.

@BenjaminNelsonX 6 жыл бұрын

Here's the video about holding up the other end of the motor. kzfaq.info/get/bejne/aNiiiNme2qqRfas.html

@davehowell3209 6 жыл бұрын

I’m loving this series that you’ve made... keep up the good work!

@junglinstinct 4 жыл бұрын

Can anyone give me some advice? I have a 1985 Mercedes T1 campervan/RV its got a 2.3l petrol engine that does about 18mpg on a good day, also converted to LPG but it does 10mpg on gas. I am thinking of hybridising it with either an electric motor from a forklift or maybe swapping out the whole engine for a Prius although the Merc is RWD and I don't know if it's possible to adapt the Prius motor to run RWD. Comments welcome!

@michaeld954 6 жыл бұрын

I want to make an electric pick up truck what motor and truck would you recommend I was thinking small tuck but want to be able to tow

@BenjaminNelsonX 6 жыл бұрын

Smaller pickups such as Ford Rangers and Chevy S10s have been some of the most popular conversions. Being able to tow is a great feature, but it runs through batteries much quicker. I tow a camping trailer with my Mitsubishi iMiEV, and towing cuts my range almost in half, but I recharge the car when I'm at the campground. Take a look at some of the trucks on the EV Album for some truck conversion ideas. www.evalbum.com/type/TRCK

@garybrown9719 5 жыл бұрын

You could get a set of transfer punches from Harbor freight Then you don't Even need a piece of cardboard just transfer the holes right on to your adapter plate Like of a machinist would doI think they're less and 10 Bucks

@nealb8169 4 жыл бұрын

I see the bell housing is removable from the rest of the transmission. Since the bell is mostly a clutch housing and a starter motor mount, why not remove the bell and attach the motor to the transmission via a smaller adapter?

@BenjaminNelsonX 4 жыл бұрын

You would basically just be re-making the bell housing, just as a different shape. The motor still needs to be spaced away some distance so that the shaft of the transmission and the shaft of the electric motor can line up and be coupled together. The bell housing makes a great solid support for the motor and spacing. A "small adapter" would still need to bolt to the rest of the transmission, support the transmission driven shaft, space the motor out correctly, and support the motor. Easier just to use the bell housing that design all that from scratch, when it doesn't have any additional advantage over the bell housing.

@JohnSmith-wo5gl 5 жыл бұрын

Shouldn't you spend more attention aligning the two shafts more accurately?

@saurabhsharma-ts6ky 5 жыл бұрын

Hi please tell me clutch is really needed in electric conversion.

@BenjaminNelsonX 5 жыл бұрын

No, you don't necessarily need a clutch. 300mpg.org/projects/electro-metro/going-clutchless/

@robertcaron9181 3 жыл бұрын

But if you have the clutch you're able to go in reverse easily with the same motor orientation, no?

@harlanbaker7476 5 жыл бұрын

What thickness of aluminum plate did you go with?

@BenjaminNelsonX 5 жыл бұрын

Half-inch aluminum plate. In the end, I just made two matching ones to double the thickness, instead of using a plate and spacers.

@harlanbaker7476 5 жыл бұрын

@@BenjaminNelsonX have you had any issues with the plate flexing? Heard that can cause concentric alignment issues

@iforce2d 5 жыл бұрын

If you don't have a 'hot rod guy' living down the street you can take the motor and the transmission to an engineering shop, and they will tear your wallet to shreds to make a very nice adapter plate. I know this because I did it.... cost me more than my donor car.

@BenjaminNelsonX 5 жыл бұрын

It's completely possible to get great results with just careful measurements, a jig-saw, and a drill-press. If a person has any friends with more experience working with metal, invite them over for a beer. There are lots of great ways to learn and do things on a budget. iforce2d, thanks for sharing the alternative!

@rajujm1 5 жыл бұрын

Hi Ben this is Raju from India I want to upgrade my 2006 skoda octavia 2gen 1.9pd disel to electric could u guide me in pdf format with spare details, I need the range of 400kms and 180bhp kind of 400nm Tourq range speed

@BenjaminNelsonX 5 жыл бұрын

Sorry Raju, I can't design a vehicle FOR you. I just try to do what I can to share and help educate people based on the projects that I've done. As always, take a look at the EV album (link in the description) to get ideas from projects other people have done. Also, please take a look at reducing your expectations of your vehicle. A car that can go 250 miles per charge and have almost 200 HP would be very expensive to build yourself. Those specs are very comparable to a Chevy Bolt, a current brand-new electric car costing $40,000 U.S. dollars.

@rajujm1 5 жыл бұрын

Tks for ur kind response

@rajujm1 5 жыл бұрын

I will go through that site tks

@jamesmason4323 5 жыл бұрын

You couldve saved a lot of time by marking it straight onto the aluminium plate.

@iforce2d 5 жыл бұрын

James Mason but then he would have wasted an aluminum plate instead of a piece of cardboard and a piece of tin when the measurements inevitably needed adjusting.

@jamesmason4323 5 жыл бұрын

@@iforce2d I've done a few things like this, so I have a few ideas about speeding up the process. Making the adapter to go between the input shaft and the electric motor shaft would be the first thing. Because the distance the motor sits in relation to the gearbox is the most important thing, so devising a way of achieving that I'd do first. Then the electric motor can be mounted to a plate. So make a plate for the motor AND a plate for the gearbox. That way you'd have square at both faces. Drill and tap the gearbox plate and they go together and because I started with connecting the two shafts, I know its aligned. Plates on both I know its square. Connecting the shafts with something like a flex disc like at the back of a BMW box would be the one. If there is ANY argument - ANY sideways pressure at all, in that shaft join, it will destroy the bearings in the motor. That has to be exact so I'd start by making that perfect. kzfaq.info/get/bejne/o8yolsaH26zVmI0.html this is my trike and the V8 I got to use in it. But actually I'm thinking of going electric with it. Electric is way lighter for the same torque.

@RamanKumar-wv2vm 2 жыл бұрын

you could trace out gasket 😂

@marquelrogers4534 4 жыл бұрын

Rather than aligning the two perfectly on a adapter plate, couldn’t you just use a chain and gears? That way only one axis has to be perfectly aligned (he depth between the transmission and the motor)

@moyzesg2186 5 жыл бұрын

Would you like to build me one and how much will you charge

@BenjaminNelsonX 5 жыл бұрын

Hello! I do NOT do custom conversions for other people, rather, I share what I learned through KZfaq videos and blogging. I have literally HUNDREDS of videos on my channel about electric vehicles, renewable energy, and DIY. Also, take a look at all the information I have posted at 300mpg.org When I originally built this project, it was sort of a "hard-core summer project". It took quite a bit of time, but the learning about it and the various challenges of working on it were enjoyable. Simply building a vehicle for somebody else would still take quite a bit of time. More likely than not, it would cost more than a modest, used, commercially-built electric vehicle. I still think that BUILDING your own electric vehicle can be a GREAT project, but it would fit in best with something that you couldn't simply buy used anyways, such as an electric truck, sports car, classic, or convertible.

@ayoub8623 3 жыл бұрын

7:28 can u go on date with me

@0MoTheG 4 жыл бұрын

At this stage of me following the build I think they will never fit sufficiently. In engineering, if your plan is build on perfect measuring and manufacturing, you are doomed.

@deadmeatdec2164 3 жыл бұрын

As a guy who makes a living building things. You sir have hit on the most aggravating thing ever. Just because it measures right does not mean it is. 3D is a pain lol