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

Keep On Pluggin

Engingeering Design Class

Good morning! Today’s lesson is how to make a structure dynamically sound and “Lookin’ Good!” The battery box mounts have gone through a metamorphosis of sorts in that they were flimsy with just the hinges holding them in place. The hinges were only the start. I then decided to design some brackets and have them fabricated by my friends at West Steel and Plastics. When I got the brackets back it was time to call in my friend Greg Hawkins so that we could properly mount the mid vehicle batt boxes and start in the the front one as well. I decided that even though the rear was being supported the boxes still needed to be anchored down so the the front to rear movement was arrested and there is no chance for the boxes to slip out of the brackets during deceleration. Using the building concept less is more I decided to use an aluminum L bracket across the front of the boxes. This addition meant I needed to drill two holes in the car and two in each batt box and four in the L bracket. Now the whole thing is modular and can be disassyembled like an erector set. It also added to the dynamic load strength of the mid batt boxes. Note no more sagging.

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Happy Kringle!

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This is my last entry until 2014. I am diligently working on the battery box bracketing system as I have discovered that the boxes need more support from underneath. This will require more engineering and fabricating. I have a plan of action which I am implementing. The battery boxes fit quite well as you can see frome the photos, however I think with the added weight of the batteries I may have some issues if I leave it like it is. So in the name of safety and common sense I am to adding a little more weight in the engine compartment. This engineering, fabricating, fitting, re-engineering, fabricating, re-fitting has been taking up the majority of my precious time which I have allotted to finish this project. I hope to show my car at EVCCON this year. Maybe I’ll see you there…

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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.

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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.

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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!

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