Saturday, May 23, 2009

Details, details...

Seems like the last 20% of the job is taking 80% of the time.

Fabricating and putting together the cooling kit for the main controller. This consists of a fan on a poly board, that blows on an aluminum sheet to which the controller is mounted.

Mounting the controller over the firewall.

side view showing the spacing of the plates.

Accelerator linkage. The pot is contained in a electrical juncton box for extra protection.

Making a new speedometer faceplate. The old one is yellowed, in MPH, and would not be calibrated because of the new transmission.

The dash mostly installed. Although they're irrelevant, the old gages are still there.
The gages for the EV functions are mounted where a radio used to be.

Putting on a door

lining the rear battery with styrofoam.
Installing PVC conduit for the the high voltage cables going to the back battery box.

Pushing the cable through the conduit at the back battery box. Baby powder makes it slide in much more easily.

Running new wiring for the low voltage side.
Laying out the control components on a board.

Friday, May 1, 2009

Getting closer to a car that starts and stops

Making a modified "dog house" to fit the transmission, using part of the original cover and sheet metal from an old 286 IBM PC.

Mounts to hold the adapter plate to the frame.

Installation of the firewall-mounted, more modern, master brake cylinder. The original was frame mounted under the driver seat.

The temperature is warming up enough to do some painting, and the car is slowly becoming more monochromatic.

The electric motor has arrived, so I am doing the final steps to fit it to the transmission. The transmission input shaft is cut with a grinder to the right length.

Bolting the motor to the adapter plate. Concentrity is achieved by the hole in the plate matching with the raised bevel on the motor face-plate.

Looking inside the bell housing at the coupler.

the motor and transmission assembled.

Lifting the motor into place.

Connecting the driveshaft.

Assembling the adapter plate bracket.

Anxious to see the parts turning, I try running the whole drive train, with rear tires off the ground, with a 12V battery.

The addition of a front bracket to support the back of the motor.