Making something from nothing

I ordered a gear off Ebay that fit my motor output shaft and had enough extra material to work with for drilling or welding. I had previously cut the center hub out of the clutch disk to have a matching spline for the transmission shaft.

The task at hand is to adapt the motor to the transmission spline.


I found a scrap 1.5 inch piece of round stock that I machined in the lathe for a snug fit of the gear and the inside of the splined core so the 2 parts would be in alignment for welding or bolting together. I will need a roughly a 3/8 spacer between the 2 parts due to the construction of the clutch center.


I found that I needed at least 1/2 inch spacer between the transmission spline and motor shaft, I found in the scrap pile a
old coupler that was 1 inch and would work.

After machining and drilling the sprocket, I snapped a tap off and had to redrill the holes as removing the tap proved to be too difficult, after assembly it was far from running true.

I was out getting some allen head cap bolts for the adapter and found a hub for a weld on sprocket, it looked to be large enough for making the adapter so I picked it up, I found that the spacer and my new motor hub outside diameter were the same making alignment easier. I fastened the two together with a hose clamp to mark and drill the holes.
I redrilled the holes, broke another tap, and put it all together with my alignment shaft. I spun it in the lathe and it ran true, success!
I put what seemed like too much time in the adapter but it is an important part and I wanted it to be right, I only used four bolts and have looked up the shear and strength numbers, with no clutch and absence of shock loads I am confident it will hold up ok. Time will tell...