On Wed, 2008-05-14 at 22:31 -0400, Seth Rothenberg wrote:
> The Kostov, is already mated to a Saturn tranny,
> so I hatched a plan to make this work. The only problem
> is a case of hardening of the axle - at manufacture time.
I've seen at least two examples of cutting and welding axles in EV
projects. I believe Otmar did this to both the Gone Postal van & his
Insight. Gone postal did break an axle but it wasn't at the weld.
You can have a new spline cut with a spark erosion machine. This is how
I intend to connect my gearbox to my wheels. You obviously need one or
other set of shafts to be long enough or fat enough to have the new
spline cut without the old spline showing through. Don't forget that you
can choose which end of the shaft to modify -- you can either adapt the
car's axles to match the gearbox, or adapt the gearbox's axles to match
the car.
I'm not familiar with modern cars, but I would be amazed if they have
standardized the speedo drive system. If the car uses a turning cable
drive then you'll need an adapter for one end as well as a gearbox to
correct the turns per mile. If it's electronic then you'll need some
sort of circuit. If one is electronic and the other a cable, then I'm
sure there are solutions for that too.
The axle machining work plus the speedo adapter may actually cost more
than an adapter plate, and you may be able to sell existing your adapter
plate.
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