Motor is installed!

Great milestone achieved! The hyper9 motor is installed and secured with the custom made mounts.

I had to replace the hub bolt with a countersunk one so that it would clear the transmission shaft. At least that was the diagnostic I made last time when the adapter plate wouldn't mate to the transmission.

Countersunk bolt on the flywheel hub
Countersunk bolt on the flywheel hub, to gain some 6 to 8 mm of clearance.

After a couple more tries (where I installed and removed the clutch and pressure plate), the issue remained, so I'm not 100% sure it was that or simply the pressure that the release bearing applies on the clutch pressure plate. The reason I'm not sure is because when I installed the thing without the clutch, the adapter plate was perfectly flush with the transmission, which means the transmission shaft was not hitting the hub. So, I decided to "squeeze" it more and bolt the two together, which apparently went well and without to much force.

Hoisting the motor
Hoisting the motor into the Samurai engine bay

Oh, I didn't need the clutch alignment tool anyway, since I could align it visually with the motor in the vertical position. Rotating the flywheel by hand helped see if it was centered or not. I didn't notice any difficulty engaging the clutch with the transmission shaft splines, so I guess the alignment tool is more suitable when installing the clutch from beneath, when you can't have the right and clear access to the flywheel.

Now, I still want to try and move the car in gear before I test the motor, so see if it engages correctly, but overall I'm very happy with the result. Plus, the whole thing seems sturdy enough and the measures seem okay.

Motor close up
Close up of the motor in its position.

Next step is do some more testing to see if the flywheel moves freely and the car can roll when in gear.
Then, add the controller and do some electrical testing with the DC power supply. It's only rated for 300W but it was enough to spin it without load. Let's see if it can spin with the flywheel and transmission.


Ken Lancaster (not verified)

I’m thinking about converting my father-in-laws old Samari to electric for my kids to drive to high school and up to the nearby mountains. I’ve really enjoyed your work log. Mainly, I’ve learned I might be getting in over my head. You have done beautiful work. Your mount looks amazing!

Sat, 2020-10-10 Permalink

Hi Ken,

thank you for your feedback and sorry about my reply delay! I didn't notice I had "unapproved" comments but hopefully I've changed that setting and also added a feature to notify about new comments so it doesn't happen again ;)

I would also love to be able to use the converted Samurai for the school runs and the odd offroad trip. That would mean both the technical side as well as the legal/regulation aspect would be done.

The conversion does require several skill sets but that's partly why it's fun. Also, it's a project so you can go on at your own pace. And you'll find people along the way that can help you with different aspects. At least that's what I found.

Best of luck!

Mon, 2021-10-18 Permalink

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