Integration test no 3 - succeeded!

I made two integration tests today and tried to mount the motor to the transmission.
After my frind Ola had machined off a centimeter of material from the flywheel it was balanced enough to test. I have been thinking of getting a special tool for centering the clutch plate to the flywheel bu now I just used a vernier caliper to measure the distance between the clutch plate and the holes in the flywheel and centering it manually. That turned out to be good enough. The garage hoist was a bless to use for navigating the 55 kg heavy motor/adapter/flywheel/clutch assembly.

Mounting the motor to the transmission

 

It turned out that the fit is so tight I could not get the motor and transmisstion together. Maybe the flywheel for the VW New Beetle, for which the adapter is originally made, has a smaller flywheel.
So, test number two failed as well.
I then removed the gear ring on the flywheel to make it smaller and shaved off a small indent on the inside of the transmission that seemed to be in the way.

After removing the gear ring from the flywheel

I used a simple propane burner that I normally use for an (other) outdoor stove to heat the gear ring and then a hammer and chisel to beat it off.

The indent before and after shaving with a angle grinder

Without the gear ring and indent I managed to push the motor and transmission together! Horray!
After reading several electric conversion blogs I now know that if you convert at car to electric you have to make a video with the first test run of the motor and transmission together ;) So, here is mine:

Motor-transmission adapter

The motor to transmission adapter arrived today from Rebbl in the Netherlands. It is manufactured by Rebirth Auto in th US for VW New Beetle. It turns out it fits perfectly on the Audi A2 1.4 TDI transmission. Apart from the M12 and M10 bolts it needs two guide pins to find the right position so I have to get those.

Tha adapter on the transmission

Also, the VW Polo flywheel fits nicely onto the adapter.

However, the bolts that I bought from a VAG shop for the flywheel didnt fit. They are thread M10x1 and they can be threaded down half a turn but then they get stuck. I also tried a normal M10 (M10x1,5) but it didn't fit either. I guess it could be a UNC thread that is used in the US so I will ask Rebbl and Rebirth Auto about it.

Different threads?

Or, I realize now when looking at thread tables that it could be a M10x1,25. Will try to find one tomorrow and test.

Wood is good!

This weekend was more thinking and drawing than building. I designed a caliper adapter plate for the rear brakes and made a mockup in wood. The mockup made me realize that I had measured 7mm wrong. Wood is good!
Later this week I will try to find someone who can manufacture the adapter in steel for me. When I get the steel adapters I will know for sure if I have measured everything right.

The wooden caliper holder adapter mockup mouted on the stub axle together with the wheel hub, brake rotor, caliper holder and caliper