Motor mounting

This is how I designed the motor mount.

First i started out by pushing a piece of paper onto the side of the motor to get an indent of where i needed to cut, then roughly cut it out and drill the appropriate holes.

After a couple test fitments and regrinding some edges it fits perfectly, a section of the motor had to be ground down and three washers were added behind the plate to clear the motor. (will get longer bolts to account for the extra thickness)

Now to start on the second plate which i already have cut out and drilled holes for in the next photo. To mount the second plate I hacked off the bushing and arm to just leave the section that bolts to the motor as a spacer for the massive bolts.

Next is to cut the square tubing to length, tack weld it in place then take it off and weld it properly.

Now to bolt the motor to the transmission and jack up the motor to the correct height and measure the length of steel to cut. I did this by holding it up to the motor/bracket and pencil tracing where i needed to cut, and cutting it, didnt turn out too bad.

Here it is fully supported by the bracket and the torque bar on the left side of the motor just to minimise any flexing.

Motor adapter plate co-ordinates

As i already had the adapter plate from the previous conversion, all i had to do was machine the holes for the iMIEVs motor into the plate.

First i measured the distance of all the bolt holes from the shaft and from each other.

Which then meant i could enter it into my CAD program and get the exact co-ordinates of the bolt holes from the center.

The co-ordinates are from top right to top left (clockwise) when looking at the face of the plate

0,0 being the center of the motor shaft

C/B is counter bored 14mm (5mm deep for alignment pins)

format: X / Y ~ hole size in mm

71.95 / 113.4 ~ 11.1mm C/B

107.4 / 0.01 ~ 11.1mm

30.24 / -103.055 ~ 11.1mm

-101.74 / -90 ~ 9mm C/B

-134.4 / 15.225 ~ 9mm

-71.95 / 113.341~ 9mm

The thread for the three 9mm bolt holes is 10x1.25mm. if you are tapping these by hand i would recommend drilling the hole 9.5mm wide as it is extremely difficult to do on a 9mm hole.

note: the pic below has all the X axis co-ords reversed as i had accidentally drawn my CAD upside down, luckily i noticed this before starting the machining process.

Using a 20mm thick adapter plate i still had to use spacers on the bolts that thread into the motor as they bottomed out with about 10mm to go.

Here's the motor bolted up to the transmission