Freelander 1 Freelander EV

I guess some loctite on the retaining screw would keep it safe.

My shaft is 21.8mm diameter.
Should I go for the 20mm or 22mm collar?

So I ordered both sizes and we'll see which is the best fit for my shaft. .

Alibro said:

The 22mm ones are 15mm wide so I would need to reduce the size of the collar to make room for it but I don't think that would cause any issues

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It should be easy enough to cut the bearing slide down a few mm.

Alibro said:

I'd much prefer to use one of these than try to stick a random blob of weld on the splines and risk getting it wrong and ruining them.

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Definitely better. A blob of weld could well weaken the spline shaft too, so best avoided really.

andyfreelandy said:

That is the Mother of all web links John !!!

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It's weird. I did wonder why there was a delay while it copied.
Sorted now.

I spent a few hours finishing the adapter plate today so it now secures to the motor using all the motor mounting bolts.



Then spent a bit more time fitting it to the gearbox. I had to remove a bit of the gearbox casing to make room for one of the bolts and make a spacer for another bolt but otherwise if fitted nicely.



Then I fitted the IRD and confirmed everything is OK.



So now I'm only waiting for the shaft clamp to arrive before removing this makeshift spacer and bolting the whole lot together

Looking good Ali. It's a compact assembly isn't it. There's going to be loads of space above it in the engine bay.

Does the coupler drive the gearbox vibration free?

Nodge68 said:

Looking good Ali. It's a compact assembly isn't it. There's going to be loads of space above it in the engine bay.

Does the coupler drive the gearbox vibration free?

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Yip, really pleased John.
There is no discernible vibration from the coupler, only gears turning so hopefully this will last a long time.

This really is a first class undertaking Ali. I'm finding it fascinating.

kernowsvenski said:

This really is a first class undertaking Ali. I'm finding it fascinating.

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LOL, I don't know about first, second or even third class but I'm having fun and isn't that the important thing?
It is to me.

It certainly is! I really hope this is succesful though too. Looking at the way you're approaching it I should say it stands a fair chance. I get a bit lost when you and the likes of Nodge get a bit technical though.

@Alibro - What have you done? It' bleeding!


Seriously though, other than the 9/16" socket as a spacer it is looking really good! I trust you are going to replace that socket.spacer with a shorter bolt in future?

In this picture of the motor mated to the gearbox...

...they almost look like they belong together.

Jayridium said:

@Alibro - What have you done? It' bleeding!

Seriously though, other than the 9/16" socket as a spacer it is looking really good! I trust you are going to replace that socket.spacer with a shorter bolt in future?

In this picture of the motor mated to the gearbox...

...they almost look like they belong together.

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LOL, I wondered if anyone would ask about the red paint.
I sprayed it through a small hole in the gearbox to mark the position of the coupler after moving it as close to the motor as it would go.
I also used it to mark one of the bolt holes where I couldn't get my bolt hole centre marker in because of the shape of the casing.

unfortunately the 9/16 spacer will have to stay. It's there because the bolt is right up against one of the motor mounts so there is no room for the bolt head. It's so tight to the motor I had to grind one side of the spacer to make it fit but there are plenty of other bolts securing the adapter plate to the gearbox so I'm not overly concerned about it.

They look like they were made to fit together because they were. I had to grind back a fair bit of the casings from the motor and the IRD to achieve the fit.

Just needs a modified bracket between the IRD, Motor & lower chassis mount to steady things as a complete assembly.

I've just spent the last 2 or 3 hours editing a video to go up on Youtube so hopefully it will be available in an hour or so.
It shows what I've done in a bit more detail.

Alibro said:

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I'm going to watch now Ali.
I may be some time.

Brill, thanks for posting. Watch your toes if it falls over again!!!

Nodge68 said:

I'm going to watch now Ali.
I may be some time.

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It was a good watch Ali. I can see you'll have a moving FL1 EV in no time!

Sorry it was so long guys, I couldn't decide if I should make it all in one or two videos but figured it probably made more sense to put it all in one.