New D&D motor won't fit, and ideas on a modification to help?

KactusKiller

I ordered a new D&D motor and went to install on my cart and it won't fit. The "windings" on the motor shaft by the yolk are flush and actually slightly protruding past the end it the motor. When I bolt it up the "windings" make contact with the face of the differential face around the yolk. The old motor was recessed about 3/4-1" from the end of the motor that bolts to the housing. I hope this paints a pic if my problem.
I have emailed the D&D rep Eric with my dilemma. Waiting for a reply but prob won't hear until Tues.
I am worried if they have another option in the same size motor that they won't take this one back because it has been mounted and a little scratched up from the install.

"If" they don't return or don't have another option here was my thought. I have the equipment to try and modify the current motor. I have other old motors at my shop. I am thinking about cutting about 1/2-3/4" of the housing off an old motor and welding it to the current motor. Then sanding it smooth and Repainting.
Can these housings be welded with a mig and will it damage the motor?

I am hoping for a better option but not sure there will be one yet.

If anyone else has an idea or experience I'm all ears.

Also this is not a regular rear axle. It is an independent suspension differential. It is basically a flat surface with the yoke coming out and a raised ring the is about 1/8" tall and fits just inside the motor housing.

BGW

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rib33024

KactusKiller I'm going to act like you didn't post that step away from the motor, and put the tools down tell us what cart your talking about, what motor did you order? what drive system your cart is. And post some pics of the motor, and we can help figure out your problem

KactusKiller

Lol, I know it sounds bad.

It is a Titan utv. I needed a better motor on because the original motor was getting hot I sent it to plum quick. That motor started smoking heavily after one time out. D&D set me up with a great motor that should do the trick. But know I have run into this problem, it won't work but has already been installed and prob not returnable without a major return charge. I just need a spacer of about 1/4-1/2". If I am stuck with the motor I have to find a way to make it work.

It is a sepex system, and the motor is a
D&D ES-132-68
48 volt
8.0 hp
16.5 hp peak based upon 500 amp controller

rib33024

So this motor didn't come out of the Titan utv?

yurtle

My concern with a spacer would be the coupler between the motor rotor and the differential input. Adding a spacer would loosen this up, and a motor has only one bearing. The "other" motor bearing is in the rear end.

Can you simply "insulate" the stator windings, or are they physically preventing installation?

KactusKiller

No it had a motor already, I am upgrading to a new motor. The new motor will not fit. I am on my phone and can't get tapatalk to post a picture for some reason since the upgrade.

The motor fits and I had it all bolted up l. That's when I realized that it was rubbing on the housing.

yurtle

Can you take a picture with your phone and plug it into a computer? That may allow you to post it.

rib33024

Are you sure the armature didn't slide out of the bearing on the end of the motor where the brushes are, what is the markings on the motor, A1 - A2 ??

KactusKiller

It's a sepex with speed censor
A1 A2
F1- F2

I'm not sure on the armiture but I don't think it slide out but I will check.

The windings a are actually touching.

rib33024

Ok your good on the sepex . not sure whats going on, but i think pics are the only thing that's going to help figure out what's up