The "Build" - Final Keyway Design - Part 2 (Final)

Today was a very good day !  At the previous initial build attempt it was found that the Warp 11 being used in the build had an obsolete motor end plate.  This older design end plate prevented the hub adapter from fully inserting into the face plate as required.  After the end plate was replaced and the hub adapter correctly installed, the critical dimension was no longer valid and John Emde at Pioneer Conversions had to precisely reduce the thickness of the spacer ring with his lathe.  After reduction of  the thickness of the spacer, and reassembly of the adapters, the critical dimension was restored.

Picture DSC05031 showing the now thinner spacer located between the end plate of the Warp 11 and the transmission adapter plate.  Note that the hub adapter shaft is now nearly fully inserted into the adapters.

Picture DSC05030 showing 35.9 amps current draw when bench top tested with a 12 V shop battery.  The motor just purrs and you can hardly tell it is even running.  Essentially no vibration!

 

 

Picture DSC05032 demonstrating the insertion of the plastic clutch plate centering tool into the bronze bearing for the  proper positioning of the clutch plate.

 

 

Picture DSC05033 showing the full clutch assembly with the clutch plate internal and the pressure plate externally secured with 6 socket head bolts.  When running the full clutch  assembly with a shop battery there is a very slight vibration.  John indicates that this will disappear when the transmission is installed in the car and the floor clutch pedal is pushed in.  The clutch pedal will at that moment dislodge the clutch plate from the pressure plate and allow it to precisely center itself on the flywheel.

 

Picture DSC05037 showing the fully assembled drive train weighing in at 343 pounds.  The drive train includes the Warp 11, hub and transmission face plate adapters, flywheel, clutch plate, pressure plate, and the Getrag transmission.

The next step is to lower the unit into the motor compartment and take measurements for the design of the motor mounting adapter that will stand on the recently replaced rubber engine mounts.