EV MX5 Conversion
(page 5)

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Drive Stubbs before machining
Sprockets after the machining
Time to get on with the drive shafts. To make life easier I bought a couple of Taper Lock Sprockets and had some 25mm bar keyed. Anything to speed the project up, having TWO children definitely slows your project making abilities down.

Then a machinist named Graham Butters machined them down for me, thank you Graham, they now fit the CV Joint on the Drive Shaft perfectly.
Drive Flange
Idler Bearing
Drive Shaft slid in to place on the Transmission..

 
This is where it got a little complicated. The transmission now fit's the car like a dream, the motors don't touch anything and everything is well proportioned. well, apart from the availability of the correct size of drive belt that is. To overcome this problem I have installed an idler pulley, this takes up some of the slack and seems to do the job, it is made using two bearings, a cheaper and more solid way rather than trying to source a factory built unit.

Tension Pulley Assembly
Tensioner Insert
And for the belt tensioning I am using a similar principle, but with a home made eccentric tensioner assembly, again using two bearings running side by side.

An additional two holes were added that are the profile of a disc grinder spanner, this will allow for easy tensioning of the belt.
MX5 Electric Transmission
Rear Profile of Tranmission
Transmission fitted to the cat without motors.

A rear view just to check the ground clearance, which was once a major concern.

Sevcon Gen4 ESC
ESC Heat Sink
Pictured are the two 72 Volt Sevcon G4 Controllers that I will be using to drive the motors.

The controllers are to be mounted on to a 5mm aluminium plate which will aid heat dissipation and to give the plate a little more help a heat sink has also been added on the underside using counter sunk bolts.

MOT Energy Motors
Motors & ESC
The mounting plates have now been welded to the top of the sub frame which support the motor controller plate.
This picture shows the Sevcon Motor Controllers mounted and power wires connected, ideal really as you won't get much loss in the wires at this short length and the controllers fit exactly where the fuel tank used to be. Mint!

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