Two Little Notches

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My record of not touching the original car had to be compromised today. I had to cut two little notches in the engine gasket rail to accommodate the rear battery boxes. For the last two days my friend Greg and I have been engineering and fabricating a cross bar which will support the lions share of the weight of the batteries in the rear battery boxes. The battery boxes in the mid engine compartment will weigh 135 lbs each. We used a 2.5″X 2.5″ Angle Iron and shaped it to span accross the motor mount and out to either side of the lateral engine mount cross member. The Battery cross bar is attached to either side with bolts and nuts to a flat plate which fits in the slot where the lateral engine mount cross member is bolted to the body. This afforded us a place to attach the battery crossmember without having to drill any holes in the car. The Boxes fit very well and are angled like a V configured motor… this one will be a V-24 as there are 24 batteries in the mid engine compartment. Very Shiek.

Keep On Pluggin

Early In The Mornin

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It is Thursday and I am waiting for my friend Greg to come down from Stockton. We have a busy day planned making brackets for the battery boxes. I have them fitted somewhat the way I want them and we are going to make it permanent today. Let me restate that, My plan or design is to be able to drop the entire drive train with the battery racks still attached very similar the original Porsche design. This may require the removal of the blower bracket. The bracket is pretty useless at this point anyway as it is about 2″ from the drivers side battery box. I may also have to slightly modify the gasket rail where the old gasket for the ICE motor once resided, and I am definitely going to have to modify the old battery tray. My biggest concern is whether or not I will have to modify the motor and adapter so that the terminal box doesnt interfere with the battery box and vice versa. By the end of the day we will know. Of course I will be filming highlights for the next movie. We are starting at 0800, so by the end of the day we should have something complete.

Keep On Pluggin

The Walk Around Movie

I decided to do a promotional video for Keep On Pluggin and the walk around for the Porsche. I didn’t want it to be your average guy walking around a car and expaining what he was doing on the car. This is the first of a series of films (videos) I will be undertaking to show the progress of this build. I do hope you enjoy it… If you do please leave a comment thank you

The Walk Around Movie

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Controller Mount

Contmount

I forgot to post this… I also submitted to West Steel and Plastics the drawing for my newly designed controller mount. The mount will be bolted to the front of the motor between the motor mount and the face of the motor. Right now I have spacers in the location just stated. The mount wil be installed so that the round part is 180 deg from the motor mount coming to a bend which will allow the mount to clear the battery boxes. then another bend and the whole thing widens into a table so as to be able to acommodate the chill plate and controller. there will be a tab cut out to mount the throttle position sensor. This tab is accomplished by cutting along the dotted line and bendingall but the tab 90 deg downward so that the end can rest on the motor adapter.

Friends and Battery Boxes

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My good friend Patrick called me today while I was working on the car. Patrick and I have known each other since high school… we were both music and theatre geeks. Patrick and I live two states away from each other. Normally I would have stopped what I was doing but it somehow felt right to use speaker phone and continue working. It was like having a friend in the shop with me. We’d talk and I would explain what I was doing and he would cheer me on. At one point I made the statement that perhaps I talk way too much about my project and the passion I have for electric transportation. He said “I find it fascinating, although I don’t always understand the technical aspects of what your doing, it is still interesting.” At one point in the conversation my battery on my phone was low and I had to plug it in at the bench. This gave me a short cord and kind of grounded me in one spot. We continued the conversation to its conclusion and I hung up my phone. I went back to work and thought what a wonderful friend have I. The phone rang again and it was West Steel and Plastics. My front battery Box is ready and could I bring a battery cell for measurement. “Of course, I’ll be right down” Wow! Just in time I thought to myself for I had just finished routing the cables from the front to the back of the car using the air injection routing. I got the box home and tried it. I planned that one as if it was a Porsche part. Wow did it fit! So now it is just a matter of two more parts and this baby is going together!

Keep On Pluggin