Torturing the Clutch in my EV

My 17 year old son recently been given a drivers license, and has, like his sister before him, taken over my EV. Free driving (Dad pays the electricity bills) is kind of irresistible. And also like his sister before him – I was full of fear and angst. You see my EV is something of a prototype, and likes to be babied by it’s Creator. Lots of traps for the unwary. If you want an EV fit for general consumption talk to Tesla.

Sure enough, just 4 weeks later, I get “the phone call” from my son. The EV has died. Motor running but making nasty sounds and won’t move. Fortunately, it stopped a few blocks from home. I attended the scene, and all I could hear was a grating sound from the front. We pushed it home and I consulted my motor vehicle brains trusts (friends Kyle and Scott) who pronounced a likely transmission failure.

I prepared to drop the motor and gearbox, something I haven’t done since I blew up the armature 6 years ago. Looking forward to the project, as doing something mechanical is a welcome change in my lifestyle. Feeling determined as well, my EV must be kept running!

I was talking about the problem on the local repeater when Gary, VK5FGRY popped up and said he might be able to help. Gary has a fully equipped workshop and years of experience with car repairs. He also has the most important resource of all – time. Gary came around this morning at 9:30am to assess the situation. He suggested we make a start, so we could at least work out what the problem was.

Within a few hours the gearbox was on the ground and the problem found – a stripped spline in the hub of the clutch plate. The noise I could hear was the stripped spline being filed away by the (somewhat harder) gearbox input shaft. Gary also discovered a few minor issues with stripped or missing gearbox mounting bolts. Note the filings on the inside of the hub, and splines mostly gone:

This was a lucky escape – I thought I was up for a new gearbox ($500 second hand). We guessed the torque of the electric motor (200Nm, about twice that of the original infernal combustion engine) had caused the fault. Well it’s been Electric for 8 years and 50,000km, so I guess I can’t complain.

We headed out and bought a new clutch plate ($100), some bolts, and transmission oil. After a nice lunch of home made bread and condiments, we picked up the tools again and by 6pm my little EV was on the road! Yayyyyyyy. Thank you so much Gary!

Here is the clutch (purple) re-assembled and attached to the electric motor, just before the gearbox was re-installed. Silver metal is the adapter plate. Lots of cables all over the place:

It was a great day. Nice change from my usual keyboard and laptop filled life. Lovely summer day, working outside with the tools, getting a bit dirty (but not oily – this is an electric car so no grease under my bonnet). So much nicer to do it with good company – especially someone as experienced as Gary.

I do live an interesting life. What did you do today Dad? “I worked with a friend to fix a home brew Electric Car!”


My EV page

My EValbum page. Lots of pictures and technical stuff.

3 thoughts on “Torturing the Clutch in my EV”

  1. I didn’t get any farther than looking at those jack-stands, and the non-blocked rear wheels? Brrrr…

  2. The jack stands are rated at 1200 kg (each), the rear wheel park brake is more effective than a house brick or chock at the rear wheels. The vehicle weight at front being considerably lighter than with the original petrol engine.

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