1962 Chevrolet Corvair Van

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First steps of making the adapter plate were done in PLA on a PRUSAXL 3D printer.

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Adapter plate prototype mounted to the Corvair bell housing and together with the Leaf motor...fitment looks good.

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Stock loaded up in a CNC mill to machine the adapter

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In three different setups the profiling, drilling, pocket milling, and tapping for both sides was complete. After machining, two 10mm locator pins were pressed into circular pockets made in the plate. These are the pins that will fit into the Leaf motor face. Similarly, pockets were milled on the Corvair side to make a transition fit with the locator pins in the bell housing.

[colincotton]

Very nice!

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We used a pre-machined EM57 coupler and combined it with the cut out center of the Corvair's clutch to create a direct drive connection between the motor and the original transmission input shaft.

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Turning down the clutch center.

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Turning down the spline coupler.

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We then pressed the two ends together and welded along the seam.