Foundry Castings Returned from the Machinist

Today we picked up the finished adapter plates from the machine shop.  These adapter plates were first reported in this blog 8/16/2012, and now two months later, we have them in hand.  The first three foundry castings were made from David's foundry mold and then a machinist used David's engineering CAD drawings for the bolt and motor placement holes.  We now have the ability to produce these adapters on demand if other EVers need them.   The next step will be to build the drive train and confirm that bolt holes and dowel tube placements are precisely where they should be.

Picture DSCN0541 showing casting after face machining, pushed against large faceplate with live center in tail stock.

Picture DSCN0889 showing active drilling of holes after CNC machine setup and programming.

Picture DSCN0909 showing finished machined surface from the Getrag transmission side view.  The holes   drilled for 14.5 mm orientation dowel tubes are located at about 11:30 and 7:00 (toward mid line).
Holes are 14.5 mm ID and 6.62 mm deep.  

(updated 4/22/2021)

Picture DSC01132 of the Aluminum dowels (2 required).

Dowels were purchased from BMW (part 11117524470 and $1.65) and were Aluminum with a 14.50 mm OD x 12.56 mm ID and 10.72 length.  The edges were beveled on the outside lip.

Picture DSC01134  showing the placement of the pair of 14.5 mm dowels on the transmission side of the adapter plate prior to using a mallet to force them into place.  A full thickness 12.6 mm pilot hole was initially drilled, followed by a 14.5 mm dowel hole that is 6.62 mm deep.  This created an internal  stop so that the dowel cannot be over inserted.

Picture DSCN0910 showing finished machined surface from the motor (Warp 11) side view.  Note that there are 12 mounting holes in the center polished surface.  These holes will allow the Warp 11 to be rotated into a variety of orientations.

DSC01669 side view of the adapter plate.

DSC01671 transmission face side.

DSC01672 motor face side.

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