11.17.12

Balance your Car, Balance your diet, Balance your life

Posted in AC 24, Batteries, Drive Train, Tuning, Uncategorized at 7:56 pm by Administrator

I had one heck of a time loosening the gland nut from the flywheel. I tried to do it using the combination a breaker bar and various methods of immobilizing a flywheel without the starter ring. Before coming up with a workable solution I broke one bolt, bent another, snapped a 914 motor mount bar, split an SK breaker bar at the swivel, and bowed a Thorsen breaker bar.
I finally cut and welded a tool that I could use to immobilize the flywheel using the clutch bolts to hold a steel plate in place. I did have to buy a very sturdy breaker bar made by a company called Proto Tools from an outfit called RAYCO. Using this new tool and a steel tube I attempted to loosen the 36mm nut again, this time with success. While applying torque pressure to the nut with the Proto bar and steel tube extender, I persuaded the thing to come loose by gently beating the life out of it with a hammer! The Proto breaker bar cost 50 dollars but when I felt that gland nut come loose, it was worth every penny. Once that task was done I took the fly wheel up to Valley Balancing and dropped it off. The whole process took two days. The next morning Steve at Valley Balancing called me and said my flywheel was ready. Ken who did the actual work has also done some work for NASCAR. I was right in thinking that the vibration was in my flywheel as he did a lot of work to get it balanced. By that I mean a lot of drilling. It was way off. I couldn’t wait to get it in the car. I was on my way home with it when I got a phone call from Cars Etc, that my 914 was ready to be picked up. They are somewhat overflowing with work and didn’t want to put the newly painted and buffed car out in the weather so I needed to make arrangements to trailer it to my house. I called Little Dave and he said he could help but his van needed new brakes and shoes. He already had the brake pads for the front and the shoes for the back so it was a simple matter of helping him put those on the van. Which we did but not before having to make a trip to the auto parts place to exchange some brake shoes which were the wrong year. Which incidentally Little Dave had purchased the year before and did not have the receipt for. O’Rielly’s auto parts not only were willing to do the exchange but Dave got $11.00 back on the deal. We finished his brakes and got my newly painted 1973 Porsche 914 roller from the shop. It was late and rain was expected that night so we dropped it off at Dave’s place under the carport. This gave me time to bring my 95 Jag back to life and move it out of the garage so that the Porsche has a place to keep out of the elements. Which is where it resides now… in my garage, out of the elements.
Keep On Pluggin

08.15.12

EVIE The Movie

Posted in AC 24, Batteries, DMOC, High Voltage System, Lets All Plug In, Low Voltage System, Restore, Sub Frame, Teardown at 10:21 am by Administrator

This is the trailer for the little movie I am making… enjoy
ACEVIE
KEEP ON PLUGGIN
This is The Movie “Gettin The Lead Out”

07.05.12

Mazda Laguna Seca Raceway, Monterey CA 07-01-2012

Posted in AC 24, Batteries, DMOC, Design, Drive Train, Gauges, High Voltage System, Lets All Plug In, Low Voltage System, Road Test, Tuning at 10:08 pm by Administrator

EV1E’s Debut as an LiFePo4 powered vehicle proved to be a success. We placed third in the “electric vehicle conversion” division (now ask me how many vehicles were in our division.) Not bad considering I have never driven on a race track. The event was wonderful and enlightening. There were more production cars then conversions. Representatives from Tesla, BMW, Coda, Nissan, as well as the Kleen Speed race team were present. This says something very positive about the future of electric vehicles and hopefully the future of our environment as well.

06.30.12

Yippee! We’re Ready to Go Dad!

Posted in AC 24, Assembly, Batteries, DMOC, Design, Drive Train, Gauges, High Voltage System, Lets All Plug In, Lights, Low Voltage System, Relay Board, Road Test, Seats, Sub Frame at 4:22 pm by Administrator

C'mon lets go!
These are my helpers. They were protesting that I couldn’t take them to Laguna Seca with me. This is an old fashioned “Sit In” They actually slept in the car last night and would not come in (the car was parked in the garage) the house.
We are ready for the big event at Laguna Seca tomorrow. Robert has volunteered his time and car trailer to the cause and we will be loading EV1E on the trailer eeearly in the morning. The Electric Automobile Association California Central Valley Chapter will be represented tomorrow!
I drove EV1E today and she “feels like a different car.” Jack Rickard of EVTV made this statement to me in one of our correspondences about the differences between lead and Lithium. He said when I change from lead to Lithium that my car will “feel like a different car” I wasn’t sure what he meant by it, I mean how could the same car feel completely different? Now I know what he meant EV1E feels more solid more responsive … tighter. Don’t know how else to explain it. Tomorrow is going to be a great way to see just what she can do.

06.28.12

Long Week, 121 Gigawatts! what was thinking!

Posted in AC 24, Accessories, Assembly, Batteries, DMOC, High Voltage System, Low Voltage System, Relay Board, Road Test, Seats at 10:49 pm by Administrator

Ok here is the scoop. Today, The Day on the calendar wherein, in 1955 Marty McFly first went back to the future in Doc’s Delorean, EV1E received her first jolt of Lithium Power. A very historic day.
As I said it was a long week. I took Monday off thanks to the graciousness and understanding of my fabulous program manager. So what did I do with it? I finished wiring the Low Voltage system. I tested all the relays and made sure they all functioned properly. I re-read the instruction manual for my PL6 which is supposed to be able to discharge a battery at 40Amps. I went through all of the steps and the only thing I got was a message that said “Bad Cell Count” and no matter what I do that is all I can get. I called Revo and sent several emails but alas a good product is only as good as the support behind it. Given that rule I have to say that the PL6 is a bad product… only because of the lack of support, that and it wont do anything useful. Did I mention I called them… this started about three weeks ago and I have yet to hear from them.
That said and done I had to figure another way to balance my pack. This took some thought…
On Tuesday I hooked up the DC to DC converter and Willie the welder came over and we welded the new seat brackets in so that I could use the 914 seats… The seats were too high, 914 seats too high! We revisited the old bradley seats and made some modifications to them and that is what I am using. On Tuesday I we also put in the locking mechanism for the aft battery boxes. On Tues night I Started placing batteries in the boxes in the proper configuration. I also fitted the connecting cables which connect the front box to the aft boxes. Wed I spent most of the day trying to configure the PL6 to discharge more then 7.99Amps. Then Willie came over again and he took the seat brackets out so that the Old Bradley seats would fit. I also pulled the three point seatbelt system out of the Porsche 914 and installed it in EV1E. I used the roll bar for the harness attachment and the other two points are where I had the lap belt. Today was great! I decided I was going to hook up all of the main pack and check all the systems. They are working. I drove the car down the block and thought this car is sluggish… I drove back home and parked EV1E in the garage and went to apply the E Brake, it was already applied. I took off the E Brake and drove to the end of the block again this time with much more pep.
About balancing. I am going to charge the pack until the most charged battery reach’s 3.5 volts then, I am going to measure the lowest voltages and take the high voltage batts out of the string and charge everything up to 3.5Volts. Then reintroduce the charged batts which were removed and have a balanced pack. I can then run the car normally until the batteries are discharged to almost 2.75V then I can hand balance them. For Now I have just a little more to do and I am ready for Laguna Seca.

06.23.12

OK Say’s Autopilot

Posted in AC 24, Accessories, Assembly, Batteries, DMOC, Design, Drive Train, Gauges, High Voltage System, Low Voltage System, Relay Board at 6:32 pm by Administrator

I have connected 4 batteries in parallel and am bottom balancing them all at the same time. Since I have to be away for a few days I thought I would Let the machines take over and when I called to check up on it I was told that they had already finished… I guess I will see soon enough, but if that is the case I will be able to do these much faster. Only a few days left and all I have to do is finish bottom balancing, hook up the main pack, hook up the DC to DC converter, weld in the seat brackets, seat belts and shoulder harnesses, adjust rear brakes, and hook up the instrumentation. Piece of cake! (gulp) Then I have to charge the pack and I will be ready to roll.

06.11.12

Just a Little Short On One End

Posted in AC 24, Accessories, Batteries, Body and Fender, Bradley GT II Electrical Diagrams, DMOC, Design, High Voltage System, Sub Frame at 11:33 am by Administrator

While I was perusing the website I noticed that for some reason I got it in my head that I would only need 7 cells on each side in the back. I can only fit 27 cells in the front rack. A quick calculation and I come up with 41 Batteries total. So we (Willie the Welder and I) are putting 8 batteries in the back on the drivers side and 7 on the passenger side giving us a total of 15 batteries in the back approx 180lbs plus the 130lbs of motor and the 40 or so lbs of Controller and the 9 lbs DC to DC converter approx 350lbs in the back and 324lbs in the front. Let me see…
Thats 684 lbs say 700 lbs which includes the motor, controller, dc to dc converter, charger and all of the batteries and battery boxes. the body with the windows and accessories weighs in at 600lbs and I dont know what a 74 VW chassis weighs so I am up to 1300lbs not including the weight of the chassis. Does anyone out there know the weight of a 74 VW chassis? The weight of the Lead acid gel batteries I am replacing was 840 lbs and only 1/3rd the energy. I think this car will weigh in at approx 2100lbs fully energized.


These photos show the passenger side battery box with the batteries in it (not final) to show how they will fit in the box. Obviously they are not ready to be hooked up. Note the pos and neg terminal placement…not correct. The second pic shows the bat box placement in relationship with the controller.

05.09.12

More Wiring, Component Placement, Door Seals

Posted in AC 24, Body and Fender, DMOC, Design, Drive Train, Low Voltage System, Relay Board at 5:25 pm by Administrator


The big news is the wiring for the motor and the controller is almost complete. It is cleaned up considerably. I have a central buss bar for my ground wires and there really isn’t that much to hooking up relays. I moved the charger to the back firewall (if you can call it that) it is now tucked neatly into the back. Everything looks cleaner. The dash board is also being re-designed…more about that later. I have ordered some more weather pack 3 way connectors. I will install those when they arrive. I have been tripping over stuff in my shop and so as to not be one who dismisses hints from the universe, I am spending the rest of the day cleaning up. Oh one more thing, Rigo from American Glass came over and checked out the EV1E’s doors and windows for leaks. He suggested I add some fiberglass strips to the door frames so the doors can be lined up with the gaskets. I looked at it and decided the aluminum would be a better choice as you can see it turned out pretty nice. I will be re-enforcing all of the doors with aluminum. I enjoy working with aluminum but it is a new concept for me. If anyone can make suggestions as to what tools I need… I have totally fried the grinder wheel on my bench grinder. It appears that a lower speed of everything is used because of the lower melting point temp of aluminum.Cutting is a problem but I find shaping fairly easy, a hand file works well for that.
Well the th th thee Thats all folks!
Keep On Pluggin

05.03.12

Operation Cleanup

Posted in AC 24, Bradley GT II Electrical Diagrams, DMOC, Design, Low Voltage System, Relay Board at 7:54 pm by Administrator

This is the DMOC and wire harness… notice anything different? Where are all the wires? If you follow from the DMOC to the back wall you will see a black cable going into the wall through a gland nut. The new location of the DMOC (controller) has advantages. I moved the relay board into the car on the back wall. Actually I have lost the board and opted for a scheme which allows me to place the relay’s closer to where they will be used.

DMOC Connected to the motor

DMOC Connected to the motor

06.12.10

Mission Accomplished! (for real)

Posted in AC 24, Batteries, DMOC, Drive Train, Gauges, High Voltage System, Lights, Low Voltage System, Relay Board, Road Test at 11:59 pm by Administrator


I drove my EV1E to work in daylight conditions and, back at night. A total of 56 miles, 26 of which was freeway driving. I didn’t push the pedal all the way to the floor but I still got 60mph on the freeway….A great day

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