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

Keep On Pluggin

Extra Extra Read All About It! Otto Is Officially a Cross Dresser!

Thats right the headlines are correct (not that there is anything wrong with that) Otto is now sporting an operational “Clutch“.  Get it?…Clutch… like “Purse“… Oh well… after I submitted the last…er… previous post I got two little pieces of hardware in the mail from Auto Atlanta and they were the only things standing between Otto and me being able to hook up Otto’s clutch. OK so maybe I’m vying for a position with The National Inquirer, at least I won’t sell my talents to  (“Fox so called news”…mjb), I would rather read accounting text books then write for Fox (“so called news”) However I am torn because I have for many years enjoyed THE SIMPSONS, I would if given the opportunity, write for that show. No I am going to be a part of a movement to better the word of reporters and better the world of having to depend on Dirty, Industrialist, Fossils.

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The Motor and Transaxle are in!!

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Things are moving rather quickly at Keep On Pluggin. Today I bolted in the motor and transaxle assembly into the car and hooked up the shift linkage and clutch bracket. I also bolted the rear bumper and valance to the car. I am toying with the idea of trailering the car over to Daves house and putting it up on his lift. You who are very astute, have undoubtedly noticed that the motor is resting on what appears to be two 2X4’s on top of a cross member. You are absolutely correct! I still have to fabricate a motor mount and of course the Batt boxes. I think I could get it done a little faster if I can elevate the car and work from under it. For now though I can still work on it and do the best I can to make it functional. Hope your weekend has been as productive as mine… until next time

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Spare Part? or Uh-Oh?

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In my last post I demonstrated how simply a motor and transaxle can be assembled and, how if one took their time and did it the right way the results will be rewarding. This post describes what happens when the careful planning and attention minded craftsman misses one little detail he noticed in a box of stuff that he was going through to find a bolt to mount the said motor and transaxle assembly into the car. When I found this said Item I knew immediatly by the shape that there is only one place on the entire car where it would fit and that place was in the middle of two really heavy components bolted together under the car in place for installation. The item is a metal gasket which protects the flywheel when the flywheel bolts are carefully torqued to 80ft/lbs. This gave me the opportunity to disassemble the clutch assembly and do a quality control check on pressure plate and clutch assembly as well as check the torque of the flywheel bolts again. At least I discovered it BEFORE I installed the motor transaxle assembly into the vehicle.

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The Mating Season

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Yesterday my transaxle found its way back home from Rancho Performance in Fullerton CA. It hitched a ride on freight truck heading North. So this morning my brother in law Tom and I revisited the flywheel/clutch assembly and checked the torque on all of the bolts. It’s a good thing we did too, the flywheel bolts were finger tight!  I knew this because I just set it up for storage until the transaxle was completed. We torqued all of the flywheel bolts down to 80ft/lbs and reassembled the clutch and pressure plate and then we were ready to mate the AC50 motor to the transaxle using Sebastian’s amazing billeted aluminum adapter. This adapter fits a few different types of motors and is stamped TOP on the back of the adapter. We lined up the motor assembly and transaxle, making sure the TOP stamp was at the top and put the threaded studs into the adapter… but… they did not line up. I knew this adapter worked because when I recieved it I checked it against the bell housing… at least I thought I did. I procured a tape measure and measured the distance between the studs. Quickly we surmised TOP actually meant RIGHT SIDE for this particular configuration. All we had to do was twist the motor 90 degrees and viola’ she lined up and almost mated right in front of us. We did have to coax her a bit but the out come is one very attractive drive assembly ready for installation.

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Lots of Work, So Little Time…

I have been working at my regular job for many days in a row. One of our nurses has been unable to come in and I have been filling in. Stuff has been getting done on the car, though painfully slow. I will be sending my transaxle to Fullerton CA next week for an inspection and possibly rebuild (the things only got 22000 mi on it) Fidel has come through and painted the rear hatch and the headlight covers, he had some issues with wind and plastic so he had to do the covers over again but man do they look great. I may be moving my shop to the foothills very soon so I am trying to get as much done before I move as I can. Many life changing things have been happening recently (all good things) so I am also still recovering from reeling. I have been offered a new job teaching at the college (or at least the prospect of a new job) I have made an offer on a house up in the foothills of the high sierras. BIG shop area. So while I am waiting to see what happens I decided to clean the so called “Hell Hole”. Its not so bad really once you get the ICE out of it. The lead acid battery reeks havoc on the passenger side right behind the firewall I am toying with the idea of mounting the chill radiator there… we’ll see. First I have to clean it, mount the motor and transmission and build battery boxes… then I can see how much room there is left to mount things. Still haven’t figured out horn problem… It just quit. I can hear the relay click but no horn. The horn itself works fine when shorted across a battery.. I will figure this out. The fog lights quit at the same time. Oh and one more thing… I found out from the Porsche Shop Manual the the directional light indicator in the dash blinks the way it is supposed to, both sides at the same time. This was a change made beginning 1973 as Forrest Gump’s momma would say “one less thing”.

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Wipers Work and Fun with Floorboards

I got the wipers to come on today (it was a relay) but now they work. The big project today was, R& R of the clutch cable.

In order to get to the clutch cable I had to first remove the floorboard which I am proud to say I was able to do (I love puzzles and how they got this design is nothing short of a masterpiece which would make a chinese box maker envious. Here you see the floorboard , what I found under it and the clevis, clevis pin and locking mechanism Last is the way I was able to stand up and work after being scrunched up in the passenger compartment. I sure am glad I am into yoga, it was very useful today.