“To clutch or not to clutch that is the question?”

Electric motors will disengage (and free spin) allowing a clutchless gear changes (since the weight of the electric motor is easily overcome by the synchomesh in the transmission). I have seen different companies advocate going clutchless and some keeping the clutch. Clutchless is simple and therefore cheaper. However I listen to the builders that advocate using a clutch and here are the reasons that resonate with me:

#Clutch gives you an emergency disconnect in case of shunt or full on condition.

#Clutchless does place higher strain on the motor and transmission,

#To make the driving experience similar to original petrol engine.

##Clutchless does require adapting driving style to correctly shift without causing serious damage to the motor.

!!!Journal entries

2009 09 16 – New clutch kit ordered

2009 10 05 – Bench testing with clutch mounted

Motor choice, many projects I found on line (see Reference designs) had used the Advanced DC 9 inch and it appears to be a very popular choice. Some other projects mentioned using a motor from Netgain have a motor called the War P 9. This motor is designed to be drop in replacement for ADC 9”, aside from have a badass name the specifications look very attractive, and it definitely looks like a step up from the ADC motor.

Netgain War P 9 “Engage the warp engine…”

!!!Specifications

Diameter: 9″ Length: 14.69″

Actual Weight: 135 Lbs.

Voltage upto: 196V HP at 89v: 28 hp

Netgain offer 2 versions, the War P 9 and the War P 9 Im Pulse, the Im Pulse is slightly cheaper (about $75 less) and offers a single shaft output, verses a double shaft on the Warp 9. The tail shaft is useful if you plan to run A/C compressors, etc.

http://www.go-ev.com/WarP.html#WarP_9

So I’m farily set on the motor (and not just because it has a cool name, although that does play a small part… *childish giggle*).

!!!Price check on retailers

(Correct as of August 15th 2008)

|!Company|!Model|!List|!Shipping|!Total|

|Net Gain (MSRP)|War P 9 impulse|$1,675.00|n/a|n/a|

|Cloud Electric|War P 9 impulse|$1,799.95|$ 82.86|$1,882.81|

|evsource.com|War P 9 impulse|$1,650.00|$ 210.00|$1,860.00|

|electricvehiclesusa.com|War P 9 impulse|$1,620.00|$ 123.49|$1,743.49|

As you can see from the prices most retailers are within a narrow range, my choice of component supplier is going to be driven by finding someone who can supply all the components give good pre and post sales support – not necessarily the lowest up front cost. Given this is my first project I will need all the help I can get and don’t want to fall into a trap with mismatched components and like to be able to leverage other experience in being successful.

!!!Journal entries

2009 06 05 – Ordered motor from http://www.grassrootsev.com

2009 06 17 – Motor arrived -ahhh…

2009 09 26 – Bench testing

2009 10 05 – Bench testing with transmission mounted!

2009 10 18 – Motor fitted

There are great many kits available off the shelf. They offer bolt together simplicity, but at a price. $500-$1000.

Here is summary of the off shelf options found on the web:

|!Company|!Clutch|!Cost|!Link|

|Electroauto|Yes|825.00|http://www.electroauto.com/catalog/adaptors.shtml|

|EV Source|Yes|848.88|http://www.evsource.com/tls_motor_adapters.php|

|E-volks|No|235.00 (coupler) + 255.00 (plate)|http://www.e-volks.com/catalog.0.html|

|EV Parts|Yes|1125.00|http://www.evparts.com/prod-AD2111.htm|

|Ecomotors|Yes|999.00|http://www.ecosmotors.com/parts.html|

Home made, no clutch option: http://www.diyelectriccar.com/forums/showthread.php/aircooled-transmission-cut-not-cuti-32991.html using a big sprocket, like this one: http://www.electric-lemon.com/?q=node/213

After discussing with Billie at Stockornaut with aid of machine shop a more cost effective solution can be made from off the shelf components.

!!!Journal entries

2009 09 16 – Crank shaft end piece back from machine shop

2009 09 26 – Bench testing completed coupler

2009 10 05 – Bench testing for final alignment

2009 10 18 – Completed coupler fitted

Advance timing of DC motors, the Motor (Wrap 9 included) can be advanced timed, this affects the positioning of the brushes, the gain in performance is offset by only being able to run the motor in one direction. So you need to be connected to a transmission with a reverse gear and you need to be careful when ordering to ensure you have the correct rotation to match the transmission forward gears on your vehicle.

Not sure which way the transmission goes, so I will push the car (forward!) with the transmission in 1st and note the rotation on the transmission spline.

Motors are orientated as CWDE or CCWDE for Clock Wise at Drive End or Counter Clock Wise at Drive End respectively.

UPDATE: Quick check in garage the drive shaft needs to go CCWDE. Found out when the Motor arrived that you can easily adjust the advance timing so no worries here.

!!!Journal entry

2009 08 25 – Transmission removed from bus

2009 09 16 – Repair steps defined

2009 09 26 – Transmission problem found and fixed

2009 10 05 – Bench testing with transmission mounted!