My method revolves around using a 'Lovejoy' coupling. This unit is rated for higher torque than my Netgain Warp 9 motor can produce and was available locally at WW Grainger. It is composed of two coupler bodies that mount to the shafts, and a synthetic 'spider' insert that goes between them. The insert allows for a little bit of shaft misalignment.
Mounting the coupler body to the motor was simple. It is just a 1 1/8 keyed shaft. However, a little creativity was necessary to mount the coupler body to the transmission shaft. I began by removing the splined center from an old clutch disk.
I disassembled the clutch disk by drilling out the rivets and removed the center. The machine shop then milled the center piece down to the size pictured above. Next, they counter-bored the Lovejoy coupler body to the same size.
After all test-fitting is complete, this piece will be inserted into the hole and have a bead welded around the top. The splined shaft of the existing transmission will then be able to slide into this modified coupling. However, the unsplined end of the transmission shaft will need to be cut off, as it cannot extend past the center insert of the Lovejoy coupling. Below is a picture of the whole assembly test fitted (without the transmission shaft inside the tube). As of this writing, everything seems to fit perfectly.
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