After working out where the motor was meant to go, we then played around with different designs for the position of the counter/jack shaft, how to hold the bearings, how to adjust chain tension, etc. before getting it fabricated.
For a while we thought about doing the work (or some of the work) ourselves but we didn't have the right tools or expertise to do it properly. In the end we got Extreme Creations (
http://www.extremecreations.com.au/) who customise motorcycles to fabricate the motor mount. Although it was a bit expensive, it's the most important mechanical part of the whole conversion and I'd rather have peace of mind than something go wrong at 70km/h! The quality of their work is excellent and I'd highly recommend them ... if you live in Sydney, Australia!
We supplied CAD drawings which were used to machine the two aluminium plates. One of the plates is welded to the swing arm whilst the other is bolted on to form a box structure. We used 16mm aluminium which seems a bit overkill but the bearings are recessed into them.
Machining the inside plate that the motor attaches to.
The slots are to adjust the tension of the chain.
Machining the outside plate.
The whole swing arm and motor weighs less than the original ICE and no more oil or petrol to worry about!
⚠️ Last edited by soyachips on UTC; edited 1 time