A New Coupler

One of the first pieces of work that I commissioned for MR02EV was the coupler, a component which connects the electric motor to the Toyota MR2 gearbox.

The First Coupler

This first version of the coupler was not very successful due to excessive slack. The spline inserted into the motor was a very loose fit and would rattle around resulting in lots of noise and making the car jump/jerk when the throttle was applied.  (Note: the MES motor has an involved spline, which is a spline on the inside).

New spine and old spline

In this close-up of the new and old splines you can see where the old spline has worn.

After several years I finally got super frustrated and asked Geoff O’Tool, a skilled friend with lots of experience in converting electric vehicles, to make me one of his couplers. These use a clutch center, custom housing and new spline (cut over size). Problem solved!