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A New Coupler

22/10/2017

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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.
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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).
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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!
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    Michael Day

    I have a Degree in Electrical Engineering from the University of Technology Sydney and am employed in Broadcast Television Industry. My hobby is the (continuing) modification of MR02EV. I am also the National Treasurer of the Australian Electric Vehicle Association.

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