Does it fit the motor?

While I wasn't able to find the exact bolts I was looking for (these are 1/4" too short), they were long enough to check the mounting hole locations. Once again, the fit was great. I had picked up washers to use with the bolts but their outer diameter is just a hair too big. I will try to purchase flanged bolts which will make this a non-issue.

Below is a view of from the top of the motor looking down. You can see the tapered section of the adapter plate significantly reduces the overall mass. Everything is lining up properly. Once I have the hub in hand, I can attach the flywheel and clutch assembly to the electric motor's shaft and test the fit/clearance of the last critical mechanical drivetrain pieces.

Try it on for size

I popped into the garage this morning to test fit the adapter plate to the transmission first (since I already had the OEM bolts on hand). Everything lined up great. Here are two photos of the test fit:

Temporary alignment pins were gently tapped into the transmission with a small hammer until they seated properly. Next, I threaded all the bolts at the bottom and inserted the longer bolts through the holes in the top of the transmission. These will require nuts and washers on the back side. Below you can see the input shaft is well centered with the motor-side pilot hole, indicating a good alignment.
This photo puts the scale of the tiny transmission into perspective. Especially considering how small a Yaris is. Speaking of small, the adapter plate weighs in at just under 12 lbs. Despite being machined from a solid piece of aluminum, the finished piece turned out relatively light.
Next up, test fitting the adapter plate to the Warp9 motor.

Sunday Sunday Sunday!

I received the motor adapter plate from my father (who lives in Arizona). He did an excellent job machining this and it was great working on this piece together via iChat, telephone calls, and email. I appreciate all the time and hard work he put into fabricating it. Sunday is the day I'll get to test fit it to the transmission and Warp9 motor. I need to pick up some proper bolts to make sure everything is aligned as it should be.

I am really anxious to get this thing put back together. Until then, here is a picture of the completed piece sitting next to the Yaris in the garage.

Fabrication: Adapter Plate (part IV)

Here's an in-progress photo of the adapter being machined. At this point some dimensions have been laid out on the electric motor face. The holes for the four bolts that secure the motor to the adapter are already drilled. Also, you can see material has been removed along the profile revealing a 1" thick flange (the piece started out 2" thick).

In this next image, you can see the whole adapter (mounted to a rotary table) angled so that a conical taper can be machined from the 1" thick flange up to the face the motor will mount to. The entire aluminum piece gets rotated as the mill cutter turns in place.
The rotary table is a heavy duty piece of equipment. Also pictured in the photo below is a dial indicator used to ensure the part being machined on the mill is perfectly flat. It can measure extremely minute changes in height as the part is moved/rotated under it.