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

11.03.12

OUI MADE THE RUN

Posted in Batteries, Drive Train, Road Test, Wipers at 7:07 pm by Administrator

I am writing this post from Jamestown, CA. It is Saturday and I… OUI… EVIE and myself, arrived unscathed and without the aid of a flatbed tow truck in Jamestown this afternoon. I left Delhi with 196Ah to attempt a 60mi uphill drive. Oui arrived in Jamestown at 1715hrs PDT with 103.9Ah left in the batteries. Did I mention uphill thats right, there is a 1329ft difference in elevation between my house (elev. 118ft) and Jamestown (elev. 1447ft.) Of course I drove conservatively but I did have my headlights on for the last 15mi. So the way I figure…
196Ah-103.9Ah/60mi=1.535Ah/mi. How did the car perform? I am experiencing vibration and I can’t tell if its the road or the car. The car was able to go 40mi/hr on some of the steeper climbs. This car may not be fast but she climbs like an elevator. This is only the beginning. Yesterday I hooked up my windshield wipers so that they park. They park on the opposite side I had them on so I had to heat them up to orange and bend them the opposite direction and temper the arms in cold H2O so they still have some spring. They look, and more importantly, function great. I am getting the garage ready to bring Otto home from Cars Etc with a new paint job. I have plenty of fresh ideas inspired by my conversing with the folks at EVCCON and Richard at ReFuel. That will be my wintertime project. Now its all about EVIE… Oh and my 50CAL BBM but thats another story.
“Keep On Pluggin”

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.

06.23.12

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.

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

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

10.24.09

New Tires and a Precision Alignment

Posted in Drive Train, Road Test, Tuning at 6:11 pm by Administrator

I got EV1E back from Bob yesterday and what a difference. Jason down at Big J Tires, helped me pick out a low resistance tire and then his team did a first class job on the front end alignment. They checked the rear end alignment and Bob Tumazi took it from there. He made the adjustment and now EV1E scoots down the road like she was meant to. I am having a special transmission re-geared for her shifting points as they are different then an ICE vehicle, that should help a little more. For the record I was keeping up with traffic on 99 when I brought her home yesterday. When I got home I had used 1% of the charge. Wow! This really works… you should get one. Next week The Body Shop.

10.15.09

Roller Bearing Smooth

Posted in Design, Drive Train, Road Test at 8:50 pm by Administrator

My friend Bob Tumazi of Tumazi Motors in Turlock CA, told me a story today about a man who, in 1965 made a Volkswagen Beetle go 58 mi on one gallon of gas. The way he did this was by making the car light in weight and using low resistance synthetic grease and oil, inflating the tires to 100psi and a real good wax job. On Tuesday I m taking EV1E to Bobs shop and dropping her off so that Bob can perform his magic. He is the only one in town that will do four wheel alignment on a Volkswagen Type 1 Beetle, and certainly the only one I would trust with a Volkswagen Type 1 EV1E. I will let you know how that goes.

08.19.09

Evie Update

Posted in AC 24, Assembly, Batteries, Body and Fender, DMOC, Design, Drive Train, High Voltage System, Low Voltage System, Relay Board, Restore, Road Test, Sub Frame at 5:56 pm by Administrator

Here are more pictures of Evie. These were taken on the 17th after I readjusted the top and doors. The doors fit much better now. What you can’t see from the pictures, I had to shave off just a sliver of the inside fender well to allow better clearance for the wheels and tires. I have decided to mount the 12 Volt fuse block/wire harness on the center tunnel behind the emergency brake. This will give me easy access. This car has a center console and all I will have to do to check or change a fuse is lift the door on the console. The console also has channels built into it which I can run my harnesses through.
The push is to get her street legal so that I can start driving her to work. Some of the members of Team Evie are coming this weekend to help. There are many rivers to cross before we get there.
Needs Top adjustment Drivers Door Front Passenger Door Before Tail Lights Front and Low

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