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

Clutchless does place higher strain on the motor and transmission, and 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 bench test, first test of motor. following the bench test guidelines very closely:

Crank shaft and sprocket welded and mounted

Motor test with flywheel

Transmission – found intact circlip! JOY.

Transmission cleaned and input shaft repaired.

Evening at Stockornaut: Crank shaft end piece back from machine shop

Sourced a large 1.125 diameter sprocket which will be welded and sleeved with the crack shaft for very solid connection.

Will use a resurfaced flywheel (original German) and brand new OE Clutch kit.

Templates for the transmission and motor being send to metal laser cut shop for the end mounting plates fabrication.

Other component updates:

Transmission – will replace main seals and investigate loose shaft, believe should be just a Circlip – if we find a whole circlip in the bottom of case – JOY, if not… mmmm…

Drive shafts, CV joints, boots – will replace with all new pre-assembled unit from So Cal, this removes any doubt about the previous condition.

Brakes – waiting on delivery of mounting brackets for upgraded front disc brakes

Batteries racks – design modification to balance to load, plan on using basic angle iron to build frame to hold batteries in place bolted through the floor.