Success! She’s Percolating! Click the Percolatin’ hyperlink for a movie

 

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After four long agonizing days of trial and error… er mostly error, I have accomplished full circuation of the cooling system. My friend Green came over while I was working on this problem and we solved it together. Percolatin’ I started this post last weekend let me get you caught up. On Monday I put the battery boxes back in the vehicle for hopefully the last time. I then filled them with batteries. Once that was done I carefully connnected the batteries to one another. I removed the DC/DC converter from EV1E and built a shelf for it and mounted it carefully running the wires and making sure everything was neat and tidy. At last the time came to test the low voltage system. I connected the last battery strap connector and heard the thing come to life, however it was not a sound I had ever heard was expecting. It was a click, click, click…etc. It sounded like a relay had gone bananas but it turned out to be coming from the DC converter. After careful examination I discovered that this converter was calibrated to be used on a vehicle with a Pack from 132-168V. I called elcon and they wanted to put me off until Monday so I called Matthew Hauber at EV West and he put one in the mail that day (yesterday). So I am in limbo with operations checking until I recieve it…probably Mon they are in CA like me. So while I’m waiting I hooked up the throttle last night and today I am hooking up the brake transducer and running the last of the wires which need to go up front into the console. I am installing a junction box in the console so that I have easy access to some of the controller wiring, this will also keep it out of the weather.  I still have to figure out an emergency shut off switch. So close yet so far away…

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Got Battery Box Back

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Thanks to Manuel and all the good folks down at West Steel and Plastics I got my beautiful battery box back today. It fits perfectly and as you can see… holds all 12 SE 180Ah batteries. Yesterday and today have been the most frustrating since I’ve started this project. To start I changed some hoses on my cooling system because I needed to clean it up. That being done I decided to test it, good thing too. It is not functioning, by that I mean the pump turns but no fluid is circulating. After agonizing over it and trying different configurations I have decided to shorten the whole system. I am mounting the cooler fan under the plate where the muffler used to be. that will shorten the system by about 10 feet. It will also put the cooler right in the slip stream under the car. Next I will be mounting the pump higher and just below the vent on the right hand side. This will put the pump where it doesnt have to pump uphill. It will also provide easier access to the pump. This must be done before I put the rest of the car together because, without cooling there is no car… not one I want to drive anyway.

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Wiring and Instruments

Pardon the pun but we down to the WIREing on this project. I have put in many more then 32hrs since my last post but as ideas keep popping up I keep going with them. The lastest idea was to get into the center section relay board and rewire it so that I can use Porsche relays for my additional relays I may install. there are at least two. I have room for four on that panel. I have also researched the idea of a temp gauge (analogue) sending unit. I have consulted with Jack Rickard of EVTV on this idea and he suggested using a water sending unit from the OEM industry tapping into my chill plate and wiring it to the gauge. This will also be what tells my fan to come on so that it doesn’t run all the time . As you can tell I have been busy. It started with removing the batteries, battery boxes and brackets from the car so that I could more easily have access to the motor and controller etc. Once I got the boxes out I realized they are only resting in one spot on the frame, for the most part they are suspended within the brackets I designed. This revalation allowed me to lose the steel bar across the top of motor mount. About 20 or 30lbs worth. I also discover that by removing 12 fasteners I can remove my entire center battery boxes. Next I made the cables for the motor to controller and bolted those in. Then came the bracket for the contactor. as you can see it looks very much like a coil. I then had to figure out how to mount the small gauge that was supplied with the controller and where to put the switch for programming. For this I used an old gauge and routed out the back so that I could slip it over the little gauge and into the center console. Thats when I got the idea for the temp gauge working as well. One thing leads to another… so it goes. So now the wires coming off of the controller are each finding a place to go to.  I also discovered that my soldering gun is due for replacement. So with all of that in mind here are the latest pics.

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Did I Say Engineering?

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Wow! That is what I have to say about the last two weeks events. First the front battery box was too short by 1/4″. Here is the lesson. Never go by the specs. Always measure. I even added 1/4″ for play when I designed the box. each battery was between 1/32″ and 1/16″ off so that by the time I added 11 batteries I was 1/2 inch off in my calculation. Since I designed it to be 1/4″ longer I was only off by 1/4″. The box is being made as I write this and should be done this next week. In the meantime I have done the following. Secured and anchored the mid eng battery boxes, connected the driveline, connected the shift linkage (final) connected the cooling system to the chill plate and bolted the controller and chill plate assembly onto the motor bracket, procured and bolted on the rear deck lid latch, bolted on the engine cover, and funnel downspouts for drainage. On Friday Solar City installed my 4.5KW solar system.  I am just about to the the point where I am only hooking up wires and testing. This is the point where one gets anxious to finish and the possibility of short cuts starts to take place. From my experience with EV1E I have decided to NOT let that happen. This car needs to be done right all the way through. This car is going to be a representation of what one can do in their own garage with just a few tools and a passion for making the world better. It must be right for people to embrace the idea.So here are a few pics, enjoy

Mark

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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.

Inspite of Myself or Re-purposing an octapus or It Works!

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Today Started out with the idea in mind to continue working on the cooling system. I was mearly going to find the pin on the relay board which turns on and off with the ignition key and somehow use it to turn on and off the cooling system with the ignition switch. Then I saw the hookup I did yesterday and realized that the hose might get in the way of the battery racks and I did not like it. Then as I was trying think of a different configuration I suddenly saw the old fuel pump on the bench…hmmm more re-purposing? YES! I swapped out the two pumps with each other and immediately saw and felt the difference, this pump was made for this car. It is quiet and pushes about 35# pressure. I was still faced with the problem that the fuel pump was part of a fuel injection system and was origianally activated by a signal coming from the pressure regulator to the fuel pump relay. I didn’t need any of that stuff. All I needed was 12 volt signal to the fuel pump relay which was activated by the ignition switch. So I started troubleshooting with a multimeter. For those of you who may be new to troubleshooting, it is basically a process of elimination. In my case I had a 14 pin connector, a multimeter, and an ignition switch. The objective was to…

a) Measure all 14 pins with an ohmmeter Locate all the ground terminals

b) Measure all 14 pins with a voltmeter with ignition off

c) Measure all 14 pins with a votmeter with ignition on

I made a little chart to keep track and discovered the following.

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Pin 8 and Pin 3 had a 12 volt signal with the ignition on. My Haynes manual has a great drawing of the relay mother board so by following where the ignition acivtated pins led I was able to jump from the power supply relay which comes on with the ignition switch, to the fuel pump relay. So now when I turn the key the car comes to life, the fuel pump relay activates, and the re-purposed to cooling pump comes on. Simple…it only took me all day…

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Hello… hello….Hello…Is there anybody out there?

Just curious… Today I finished hooking up the cooling loop minus the chill plate to see if there are any leaks and if there is adequate circulation. I am happy to report all systems go! It was necessary to figure out how to turn on the fuel pump circuit as it was activated by the fuel injection computer which I did remove and sold with the motor. I got out the schematic and thought “hey I can reinstall the circuit board and have pleanty of hot wires for hooking up the electronics later ie controller etc.” I found the relay that activates the fuel pump and using a jumper sent a signal to the circuit… worked like a champ. So I am going to keep yet another part I thought I would not be using. This is getting good… re-purposing is very much like recycling… its fun when you get creative.

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Re-Purposing an Old System

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I want to plumb the cooling system for the controller prior to putting in the battery racks. I have been thinking about this for quite some time. One thing I learned from building EV1E is the importance of keeping the cars wiring, vents, fuel lines, air injection system, intact as one might find a use for these seemingly nonsensical  extras later down the road. By nonsense I mean for example,  what on earth do you need a fuel system for in an electric car?  You don’t but you can use the fuel lines which are already plumbed from where the gas tank used to be to where the engine used to be which is perfect for my re-purposing project. I am putting the Radiator and fan in the front of the car which ironically is where the gas tank used to be then I am running my hoses to the back of the car which again ironically is where the the fuel pump and engine used to reside. In between these two places are two beautiful fuel lines which run the length of the car. when I saved them I thought they might make a good conduit or something… this is even better. The pump I purchased from EVTV MotorVerks is about 2mm bigger in diameter then the original fuel pump I only had to swap the bracket and it mounts in the same place the fuel pump did. The wiring harness has the connector for the fuel pump right there I only have to plug it in.

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Interesting Idea…

Today is Tuesday OCT 1 2013 and I fell asleep watching the Beatles Anthology when suddenly I was awoken with an Idea. Hypothysis… why can’t I use the fuel pump system for a cooling system for the Porsche 914, or any other vehicle? This would eliminate having to re-plumb the car and obviously there would be an already plumbed former fuel system to tap into on any former ICE vehicle. It is now 2240 hrs and I am excited about this prospect. I have just hooked up my fuel pump to my power supply at 5 volts and it ran just fine! Of course my hands smell like old gasoline and I will have to research why there are three orifaces on the stock fuel pump, but I think I may be on to something. Why can’t we pump Ethylglycol and H2O through the same system? Maybe it’s the gas fumes … but I think this may work! I will let you know…

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