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I decided to do the flywheel a little differently than usual. I chucked it up in the lathe and machined a hole the size of the taperlok adapter. I then pressed the adapter into the hole and welded the back side of the joint. This pulls the flywheel closer adapter plate and removes the need for any spacers.

Here is the view of the flywheel with the flange welded onto the backside

Here is how the flywheel looks mounted onto the motor. There is no need for any motor spacers. This assembly is about 3 1/2 inches shorter than using a flywheel adapter which has the added advantage of keeping the flywheel closer to the support bearing.

Here is a view of the flywheel mounted onto the motor shaft. notice that I have bored a pilot hole in the end of the motor shaft to support the clutch shaft.

The motor is in the frame with the clutch installed. The wires connected to the motor are only temporary. They are the ones I used to run in the brushes.

The lovejoy connector is now fitted to the other end of the motor.

Here is the other half of the lovejoy on the generator head. I'm using this to provide regen. It will be actuated when the foot is lifted from the throttle pedal and increased with a sliding pot on the brake pedal. The relay for the regen contacts won't make until the main contactor for the Zilla breaks.

Here is an adapter flange that I made up to connect the motor with the generator.

This is a view of the speed sensor. I put it on the end of the generator since this seemed like the simplest solution. Because the two units are coupled together it should work fine. It might even help since the sensor is further away from the motors magnetic fields.

Here's the whole thing stuck in the car. It fits! With about a half inch to spare.

 


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