tag:blogger.com,1999:blog-24564305709666067352024-03-04T23:52:48.118-08:00EV-A40 :The restoration and conversion to electric drive of an 1954 Austin SomersetDrDonhttp://www.blogger.com/profile/00507851363454428274noreply@blogger.comBlogger17125tag:blogger.com,1999:blog-2456430570966606735.post-75074727345457526072010-11-21T16:23:00.000-08:002010-11-21T16:56:35.507-08:00EV season done for 2010<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrPVWDVPUS1yNPMr0tLWyVmTa_lVCX_zqZoYyzTJwZIMOjd-2p_qm4DBSpdbLYLQ2q7GguZGBXFUJEMk5dGkrjoUonMjR_uT9HHzzz2Uz4NNlvziJcast9FfUz6N6xI1x0CjIUggn4Xllq/s1600/IMGP0451.JPG"><img id="BLOGGER_PHOTO_ID_5542163983875505714" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrPVWDVPUS1yNPMr0tLWyVmTa_lVCX_zqZoYyzTJwZIMOjd-2p_qm4DBSpdbLYLQ2q7GguZGBXFUJEMk5dGkrjoUonMjR_uT9HHzzz2Uz4NNlvziJcast9FfUz6N6xI1x0CjIUggn4Xllq/s320/IMGP0451.JPG" border="0" /></a><br /><br />November 20, the last ride for 2010. The car rolled up 6630 kms (3770 miles) this year. Total EV kilometers is now 9160 (5730 miles<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiF4bA38VU2TapNbbdUF01yo2ej-pL9CWt0BtA4TBdYuZosHMUVEdCVkx4-83CVh_2FAXzIES2selk6dx1BoOdi4kHHd8HqSTCguQ6qPGzFyLzFL_W0EBervgSMh8gHpdXl_jPpdgUzx4hI/s1600/IMGP0162.JPG"><img id="BLOGGER_PHOTO_ID_5542169195312567074" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiF4bA38VU2TapNbbdUF01yo2ej-pL9CWt0BtA4TBdYuZosHMUVEdCVkx4-83CVh_2FAXzIES2selk6dx1BoOdi4kHHd8HqSTCguQ6qPGzFyLzFL_W0EBervgSMh8gHpdXl_jPpdgUzx4hI/s320/IMGP0162.JPG" border="0" /></a><br /><br />The only incident I had was coupler came loose, and slided toward the motor, and jammed itself in the motor faceplate. A spacer will now prevent that. I also needed to replace the potentiometer due to erratic acceleration.<br /><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhz3xexnzStnsfO30Xu6fe23C11fcvWeIlTfkvp_Nf48iZ7GwSWcx2WG7NXsmv2j2uxuYm8THdDlnwcWO_9EC3U4PBmeT7_uBU9vUeVsT8HpivNAF-aw2GYpK4riWkisiqpcRx-HMrnnGeg/s1600/IMGP0179.JPG"><img id="BLOGGER_PHOTO_ID_5542166210711356290" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhz3xexnzStnsfO30Xu6fe23C11fcvWeIlTfkvp_Nf48iZ7GwSWcx2WG7NXsmv2j2uxuYm8THdDlnwcWO_9EC3U4PBmeT7_uBU9vUeVsT8HpivNAF-aw2GYpK4riWkisiqpcRx-HMrnnGeg/s320/IMGP0179.JPG" border="0" /></a><br /><br />Showed the car at some events during the summer: Here at the All British car show<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1KyPbcW27a64NOw5l0DDdV5iZxIGkEUYog3GtcxRY2ivkwIIwJU3gu_P0ilxmhkK_fXdZ_frNX3MNy4cs6xvPhGhcW-xzQsw-s6taedi5Y_ntCHf5SZMThb_63JJ7qXMXxIGD3lFPRLbr/s1600/IMGP0224.JPG"><img id="BLOGGER_PHOTO_ID_5542166958505673266" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1KyPbcW27a64NOw5l0DDdV5iZxIGkEUYog3GtcxRY2ivkwIIwJU3gu_P0ilxmhkK_fXdZ_frNX3MNy4cs6xvPhGhcW-xzQsw-s6taedi5Y_ntCHf5SZMThb_63JJ7qXMXxIGD3lFPRLbr/s320/IMGP0224.JPG" border="0" /></a><br /><br />Cruizin-Downtown show<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYci4_t-su8y26E6ZmQaBmmhwqb3lu8ey9uVskHWK57ZniD3xmm-2xJIGkvYdGwsuwEOSi8XGfuY4fOyaKjN4vwppTO5RCd9f9MsFcIk0QPxrohxlf-eHXrZKQJFecuNXkIcslgBbjRkZU/s1600/IMGP0221.JPG"><img id="BLOGGER_PHOTO_ID_5542168334443979442" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYci4_t-su8y26E6ZmQaBmmhwqb3lu8ey9uVskHWK57ZniD3xmm-2xJIGkvYdGwsuwEOSi8XGfuY4fOyaKjN4vwppTO5RCd9f9MsFcIk0QPxrohxlf-eHXrZKQJFecuNXkIcslgBbjRkZU/s320/IMGP0221.JPG" border="0" /></a><br /><br />Queuing up for the Flashback Weekend parade.<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrekdI-T7gPwVtSel3KXICt1ZKRaJ76riPpTqZFtOd4FGjVPptK3P70-S4ZLWFsppsXCXgeI1hGqJodzLZP9wMxoT7r1r5F4An58UILp-1mjbKAgkeSfKPWJfEwcwErPVaqViyFhuf1EjG/s1600/IMGP0231.JPG"><img style="float:left; margin:0 10px 10px 0;cursor:pointer; cursor:hand;width: 320px; height: 240px;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgrekdI-T7gPwVtSel3KXICt1ZKRaJ76riPpTqZFtOd4FGjVPptK3P70-S4ZLWFsppsXCXgeI1hGqJodzLZP9wMxoT7r1r5F4An58UILp-1mjbKAgkeSfKPWJfEwcwErPVaqViyFhuf1EjG/s320/IMGP0231.JPG" border="0" alt=""id="BLOGGER_PHOTO_ID_5542170923321135074" /></a><br /><br />Just driving aroundDrDonhttp://www.blogger.com/profile/00507851363454428274noreply@blogger.com1tag:blogger.com,1999:blog-2456430570966606735.post-48824605591384683602010-03-02T19:16:00.000-08:002010-05-26T20:30:48.061-07:00Winter updates<div>An extended fall season has allowed driving my car till November 29, 2009. Driving and charging every day could maintain the batteries at ~15 to 20 Celcius, despite sub-zero outside temperatures. Skipping a day or two of driving, and the batteries got below 10C, and range would be seriously affected. A heat source in the battery boxes is needed.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgiUT3aSilXZDkR1KByQKmIiI7ayv-Cis-urqdrcCbEGbiZjpjolCzVksuuWl-wiU5fxiNnd7t78O_krqmTqiq1kLyovRXeKuZK0nfQWyF2KQTomX-T44K78zqwIMXnTtbOorJhZpV51DPs/s1600-h/IMGP0078.JPG"><img id="BLOGGER_PHOTO_ID_5444245930304629730" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgiUT3aSilXZDkR1KByQKmIiI7ayv-Cis-urqdrcCbEGbiZjpjolCzVksuuWl-wiU5fxiNnd7t78O_krqmTqiq1kLyovRXeKuZK0nfQWyF2KQTomX-T44K78zqwIMXnTtbOorJhZpV51DPs/s320/IMGP0078.JPG" border="0" /></a><br />As a heat source, my plan is to use the heating wires from automotive battery warmers. These consist of filaments looped and glued on an aluminum foil backed with a fibre insulation and packaged in a sealed bag. Here, I am stripping out the heating elements components from the bags.<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6-34jnuJvcLnBUMJS-x95693BFmVYM8fY3gMTVVdegQe_2w3fjxSgi_vl4tujdpvayDybfHxD3ArCfZC7Vce9ppWEgHgNqr6ek8tezw6f8OewgRt88jXROqAvpzTeoOTaDHRVkhtffA2R/s1600-h/IMGP0080.JPG"><img id="BLOGGER_PHOTO_ID_5444245744897327154" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6-34jnuJvcLnBUMJS-x95693BFmVYM8fY3gMTVVdegQe_2w3fjxSgi_vl4tujdpvayDybfHxD3ArCfZC7Vce9ppWEgHgNqr6ek8tezw6f8OewgRt88jXROqAvpzTeoOTaDHRVkhtffA2R/s320/IMGP0080.JPG" border="0" /></a><br />To help dissipate the heat across the bottom of the box, the foil will be contact with a thin aluminum sheet (roof flashing, actually).<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitM05ZlZGf5A0uIGPjo6HR4RqPEFl_Y0w3SPdNAQXjiM8ghIEp4Jos0IYlZTOGCQCVFzjcokDmvJ0YNlzwYmYGlakjz123rUsVwHka7NoIekJrRy1piXcDHpv_AOA3d2v9om_X9jC4wOF9/s1600-h/IMGP0081.JPG"><img id="BLOGGER_PHOTO_ID_5444245142802921538" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitM05ZlZGf5A0uIGPjo6HR4RqPEFl_Y0w3SPdNAQXjiM8ghIEp4Jos0IYlZTOGCQCVFzjcokDmvJ0YNlzwYmYGlakjz123rUsVwHka7NoIekJrRy1piXcDHpv_AOA3d2v9om_X9jC4wOF9/s320/IMGP0081.JPG" border="0" /></a><br />Here, the aluminum sheets are sized to cover the bottom of the boxes, and the batteries go overtop. hopefully, under the weight of the batteries, the foam will give way and not crush the heater wires. This is front battery box.<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEifcvmZiy97Zc5JX-m8fO7taifWvpWfwjudUdWXgyxcfv4Ya43SpbY8-6Tq7Og7MN3D1zEqHfK2F0g5T69EnAGgbgljt_xtq4oi5oNVrG8cjdQIae16C0xwfEsM5v2-nNL7dC5pDZ83Zpgz/s1600-h/IMGP0084.JPG"><img id="BLOGGER_PHOTO_ID_5450516609290378642" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEifcvmZiy97Zc5JX-m8fO7taifWvpWfwjudUdWXgyxcfv4Ya43SpbY8-6Tq7Og7MN3D1zEqHfK2F0g5T69EnAGgbgljt_xtq4oi5oNVrG8cjdQIae16C0xwfEsM5v2-nNL7dC5pDZ83Zpgz/s320/IMGP0084.JPG" border="0" /></a><br />The rear battery box.<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCcojusVqN8ForU_9VkOd8Us4ByjpoYmyW_1C9pYUK8HFnDSwP-9I9nZR1Rd9MpYzneeCkZ888j5Onr6DH5cisFr-6iCp8rkpXCnL0tYHqbf2k3ECJ5keNqbJC1Lq3ca-YAFK3d61AJGBH/s1600-h/temperature_controller.jpg"><img id="BLOGGER_PHOTO_ID_5444264384233752098" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 234px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCcojusVqN8ForU_9VkOd8Us4ByjpoYmyW_1C9pYUK8HFnDSwP-9I9nZR1Rd9MpYzneeCkZ888j5Onr6DH5cisFr-6iCp8rkpXCnL0tYHqbf2k3ECJ5keNqbJC1Lq3ca-YAFK3d61AJGBH/s320/temperature_controller.jpg" border="0" /></a><br />The heating is controled using a terrarium temperature controller, one for each box. <br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiErtIrNKgkXGLjYcXiK6HwicbuRtNMVY6SekTqA5A5mIPs9v5b7Tn83RGEw7en5eNnHbB960F47EAxBYoFw-yOvrQm6OkhwuQOlDOS0nqopoGsQN3JvqNu3T3mYlEqhpLK0CstAQSDqXdQ/s1600-h/IMGP0082.JPG"><img id="BLOGGER_PHOTO_ID_5445008188534194786" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiErtIrNKgkXGLjYcXiK6HwicbuRtNMVY6SekTqA5A5mIPs9v5b7Tn83RGEw7en5eNnHbB960F47EAxBYoFw-yOvrQm6OkhwuQOlDOS0nqopoGsQN3JvqNu3T3mYlEqhpLK0CstAQSDqXdQ/s320/IMGP0082.JPG" border="0" /></a><br />The long wires for the power and thermocouple permit mounting the temperature display just below the dash. </div><br /><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiG9gGEAYQBZ_ILE7tQE7pSCOg9mLF2l2w82riOYAGewab0JdSXtEQIveU7xhnFq4JHfjC-OU1_14q84FCatZ5RVTQIU4XUEo8i-5Y1qDHveH8FG2ubOgkB3fZphr25RIsYS3o8EYeO6NvR/s1600-h/IMGP0087.JPG"><img id="BLOGGER_PHOTO_ID_5450515800274993298" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiG9gGEAYQBZ_ILE7tQE7pSCOg9mLF2l2w82riOYAGewab0JdSXtEQIveU7xhnFq4JHfjC-OU1_14q84FCatZ5RVTQIU4XUEo8i-5Y1qDHveH8FG2ubOgkB3fZphr25RIsYS3o8EYeO6NvR/s320/IMGP0087.JPG" border="0" /></a><br />To help have a stable temperature measurement by eliminating drafts, the thermocouple is suspended in the a form doughnut.....<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-fe-S2ct5vL_0p4NIhkLpqddczjiLcxr-qANuw8iBIMBSFVvkANjuR652PbKj90mr4ZH9O3cpg8_zZAMH9p1RiTKr7hPia59btYLaJcefavg91OWq0KlSi_YiHPfgXTbZAgJd6ZruY_2V/s1600-h/IMGP0088.JPG"><img id="BLOGGER_PHOTO_ID_5450515935520309650" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-fe-S2ct5vL_0p4NIhkLpqddczjiLcxr-qANuw8iBIMBSFVvkANjuR652PbKj90mr4ZH9O3cpg8_zZAMH9p1RiTKr7hPia59btYLaJcefavg91OWq0KlSi_YiHPfgXTbZAgJd6ZruY_2V/s320/IMGP0088.JPG" border="0" /></a><br />.... which is stuffed in between the middle two batteries.<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFnzU6Krn6Gi0deldpOBfjmcNyPYm8VxlrYs9F1G-LPeIe9hUbzW-XcHwLMb-TbdMpAi3Wlv5V0mUJQBgg_4X6M_nkgkt50GubsN1RcWb58ejZgmKnewbzEaE8ssPDDum9x-WDsZw1ktXx/s1600-h/IMGP0089.JPG"><img id="BLOGGER_PHOTO_ID_5450515556764537186" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhFnzU6Krn6Gi0deldpOBfjmcNyPYm8VxlrYs9F1G-LPeIe9hUbzW-XcHwLMb-TbdMpAi3Wlv5V0mUJQBgg_4X6M_nkgkt50GubsN1RcWb58ejZgmKnewbzEaE8ssPDDum9x-WDsZw1ktXx/s320/IMGP0089.JPG" border="0" /></a><br /><br />It takes about 4 hours to get to 20C from 10c<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgl8xTWzmx5uoOrwAVYOAGIpOFOgtvoUKyX7zFDEQ5YPIGYTxKhCkEG9rd3xQsD9HG_SjDGNuYZhiBbtEO255LYxTnmS7_wcTlKYfgQMj_ZRz32z15JkQvEkBed69mrd6OnVo1T1p1lvsRR/s1600/IMGP0053.JPG"><img style="float:left; margin:0 10px 10px 0;cursor:pointer; cursor:hand;width: 320px; height: 240px;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgl8xTWzmx5uoOrwAVYOAGIpOFOgtvoUKyX7zFDEQ5YPIGYTxKhCkEG9rd3xQsD9HG_SjDGNuYZhiBbtEO255LYxTnmS7_wcTlKYfgQMj_ZRz32z15JkQvEkBed69mrd6OnVo1T1p1lvsRR/s320/IMGP0053.JPG" border="0" alt=""id="BLOGGER_PHOTO_ID_5475778490799666786" /></a><br /><br />Modifications were made to method of mounting the motor and transmission, to use a cage structure that support points that use the original rubber motor mounts.<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrFePt1zT8VzFgMAuKSHZ05WN4IvBaC51c6K62GE63mTTGhYj8WnwbiBdW5j5d0ABR0PGp-ztBI_8hEvojAec3SYVSrcv5hq1volXj7e4nRX5bb34uorb4auWMrXNK3vEt19H0qJBL_5w8/s1600/IMGP0062.JPG"><img style="float:left; margin:0 10px 10px 0;cursor:pointer; cursor:hand;width: 320px; height: 240px;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrFePt1zT8VzFgMAuKSHZ05WN4IvBaC51c6K62GE63mTTGhYj8WnwbiBdW5j5d0ABR0PGp-ztBI_8hEvojAec3SYVSrcv5hq1volXj7e4nRX5bb34uorb4auWMrXNK3vEt19H0qJBL_5w8/s320/IMGP0062.JPG" border="0" alt=""id="BLOGGER_PHOTO_ID_5475785338181449570" /></a><br />The motor-transmission assembly in the car.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixUBCh9sihsSeRUFTkvcDSu2gLxLuOPo1bI6Dt7I8wqONIu7ZQD1De1buB6N8-QmvowTb3NRTAXF2HTcNxhAe9Lkxlh8s92xMnafy3IDs1E0-AsrMnkt8G8c5FqoH1s285EAFHROXOw6ft/s1600-h/IMGP0094.JPG"><img id="BLOGGER_PHOTO_ID_5450515184095180818" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixUBCh9sihsSeRUFTkvcDSu2gLxLuOPo1bI6Dt7I8wqONIu7ZQD1De1buB6N8-QmvowTb3NRTAXF2HTcNxhAe9Lkxlh8s92xMnafy3IDs1E0-AsrMnkt8G8c5FqoH1s285EAFHROXOw6ft/s320/IMGP0094.JPG" border="0" /></a><br />Keeping it simple, the spash guard for the motor.....<br /><br /> <a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRUF5gBrp2zjuufCIJ41kpLp7MhXE8iJoge_8SF5uBS_J6KAWvvXnMM39y4tFQY6iFOGPKnRY8jeW_nlD1Uz4t3-hKhC5-urvtZgQpE0xYRBKvGxJRh2e0-LfkkJO_PZDj5jLFqBQTw9qq/s1600-h/IMGP0095.JPG"><img id="BLOGGER_PHOTO_ID_5450515352811247218" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiRUF5gBrp2zjuufCIJ41kpLp7MhXE8iJoge_8SF5uBS_J6KAWvvXnMM39y4tFQY6iFOGPKnRY8jeW_nlD1Uz4t3-hKhC5-urvtZgQpE0xYRBKvGxJRh2e0-LfkkJO_PZDj5jLFqBQTw9qq/s320/IMGP0095.JPG" border="0" /></a><br /><br />... installed.DrDonhttp://www.blogger.com/profile/00507851363454428274noreply@blogger.com3tag:blogger.com,1999:blog-2456430570966606735.post-22408270921947621582009-10-13T19:32:00.000-07:002009-10-13T19:45:16.424-07:001300 miles and counting<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgxYbvJjm3Y_vPVgzkEKN7l_KAaeWbmd8FSy9pGlPeEMl45ShbwNMCXO0v-EndtjnpxsdKkUC8PcFYIPJBNymqLmePe_XT_lorqIldbALEqrqkelztNHhPXYiGzGKzOViU-qHvChw8w_07D/s1600-h/IM000751.JPG"><img id="BLOGGER_PHOTO_ID_5392278166299298626" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgxYbvJjm3Y_vPVgzkEKN7l_KAaeWbmd8FSy9pGlPeEMl45ShbwNMCXO0v-EndtjnpxsdKkUC8PcFYIPJBNymqLmePe_XT_lorqIldbALEqrqkelztNHhPXYiGzGKzOViU-qHvChw8w_07D/s320/IM000751.JPG" border="0" /></a><br />Its been a while since my last post, as I've been driving my ev. The driving season is almost done as I won't be driving in the snow. I have done about 1300 miles so far with no problems.DrDonhttp://www.blogger.com/profile/00507851363454428274noreply@blogger.com2tag:blogger.com,1999:blog-2456430570966606735.post-51501003424095488802009-07-23T20:09:00.000-07:002009-07-23T21:01:18.347-07:00<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8JbbY4Q0NA5DHe-kT_-nh7ppEZ3OenkssMzHKD9ZYiirAgjI66Uhc2AjQD9G1cPvi5LAV4lODw-RCs5j0QP4mpvx2bOR6a0h_2EteCdHdm1CI7FMtBcIfymEe0U6q6Ml6ffeP6wxxdzHI/s1600-h/IM000688.JPG"><img id="BLOGGER_PHOTO_ID_5361865429216047666" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi8JbbY4Q0NA5DHe-kT_-nh7ppEZ3OenkssMzHKD9ZYiirAgjI66Uhc2AjQD9G1cPvi5LAV4lODw-RCs5j0QP4mpvx2bOR6a0h_2EteCdHdm1CI7FMtBcIfymEe0U6q6Ml6ffeP6wxxdzHI/s320/IM000688.JPG" border="0" /></a>I got my saftey inspection done with no problems, and rolled up about 50 miles on the car and got some ideas on how to fine tune my design. I figure a better location for the controller would be nearer to the front of the vehicle. Taking the controller out out of the car to start on this work, I notice something loose is rolling around inside. Doesn't sound good, so I return the controller for warrantee repair.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhz2HyziKnLfZz8f4YcRhSP5efS8N_R2z7gb0NiMEMi_AECTPQLl5lEKbMbjArpGE522B0QqXemJ9W6H4fzFf_xMQOzlG6GbOtoE1oRC8Hy4iRoTiuFbyVdR8xrMDOTOqG80RPS3vVT8vkL/s1600-h/IM000698.JPG"><img style="float:left; margin:0 10px 10px 0;cursor:pointer; cursor:hand;width: 320px; height: 240px;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhz2HyziKnLfZz8f4YcRhSP5efS8N_R2z7gb0NiMEMi_AECTPQLl5lEKbMbjArpGE522B0QqXemJ9W6H4fzFf_xMQOzlG6GbOtoE1oRC8Hy4iRoTiuFbyVdR8xrMDOTOqG80RPS3vVT8vkL/s320/IM000698.JPG" border="0" alt=""id="BLOGGER_PHOTO_ID_5361869238462449986" /></a><br />I found a new home for my old engine and associated parts with someone I met who is planning to restore an A40. Its good to see these parts may get reused.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6rrFGKUysGS0ZQqfctXzSWkPFyE0d2kXgR3hgOl7rdo69pTlgmcEPW1-ICGBy6fa2Pqq3-IuaALJUOVZ10UeyQzngurS6rdGwSuVXNhFmzvBukbXEDduOm-LWiqAJjT-upOVQxZw3b3ZL/s1600-h/IM000695.JPG"><img id="BLOGGER_PHOTO_ID_5361864937515288130" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6rrFGKUysGS0ZQqfctXzSWkPFyE0d2kXgR3hgOl7rdo69pTlgmcEPW1-ICGBy6fa2Pqq3-IuaALJUOVZ10UeyQzngurS6rdGwSuVXNhFmzvBukbXEDduOm-LWiqAJjT-upOVQxZw3b3ZL/s320/IM000695.JPG" border="0" /></a><br />The car is out of commision while the contoller issue gets resolved, so I work at making the covers for the battery boxes.<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEiAiAfHkaCoMFBplIIEx3wktRIUmBMh-nhbfTNC2HbhI-qBbQ4iiiuDyIsgSsM0_it2UFJvhixvk62zHq7Yl8k-9gPa64uHuAde7vihl1Rf4hL9ol3CsnWUGvIB3DKzLRgnQaSQtdNLM-/s1600-h/IM000691.JPG"><img id="BLOGGER_PHOTO_ID_5361861499274675730" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjEiAiAfHkaCoMFBplIIEx3wktRIUmBMh-nhbfTNC2HbhI-qBbQ4iiiuDyIsgSsM0_it2UFJvhixvk62zHq7Yl8k-9gPa64uHuAde7vihl1Rf4hL9ol3CsnWUGvIB3DKzLRgnQaSQtdNLM-/s320/IM000691.JPG" border="0" /></a>Also after driving the car, I found the transmission to be rather noisy. The transmission mounts are rather hard, so perhaps something more pliable would be better, so here is motor coming out.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixjBGSEhhgrIPE2z-_R0a_V90nCDpFOIQYTFrssc6Ihgifjow5RceS2N74NQ1DQroDP-gckbTgF2mZO0QlELktu5bZcjeGYiRuk7xe2vP8T3MnMoSnlkXGN8VX314nXe2SDnTKL5pv8LpD/s1600-h/IM000690.JPG"><img id="BLOGGER_PHOTO_ID_5361864046588066370" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEixjBGSEhhgrIPE2z-_R0a_V90nCDpFOIQYTFrssc6Ihgifjow5RceS2N74NQ1DQroDP-gckbTgF2mZO0QlELktu5bZcjeGYiRuk7xe2vP8T3MnMoSnlkXGN8VX314nXe2SDnTKL5pv8LpD/s320/IM000690.JPG" border="0" /></a><br />Using the opportunity to inspect the coupler. While only after 50 miles, they look like new.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVDWc2x8iRA4ul32_MW7sBz7HFMeTDthfsh0X0Vu4ZjXDjqFzJbEcj0SN1BHYO5Vf75444UsXJB0th54HaeT3WqS4mhoxAdcLGmLRIRpk-FNqRBMspBM5-Cfp092PEj1LOb7iq3cOyUEjj/s1600-h/IM000692.JPG"><img id="BLOGGER_PHOTO_ID_5361863369769779218" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVDWc2x8iRA4ul32_MW7sBz7HFMeTDthfsh0X0Vu4ZjXDjqFzJbEcj0SN1BHYO5Vf75444UsXJB0th54HaeT3WqS4mhoxAdcLGmLRIRpk-FNqRBMspBM5-Cfp092PEj1LOb7iq3cOyUEjj/s320/IM000692.JPG" border="0" /></a><br />The transmission reinstalled, with mounts made from nested rubber hose.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzSbOG6cSMpHIVRDOVSn_TSD6C17-XqxjhdpwKw1GGZr-WIo0ETsdSFeVgSB08-0GfaLBY64eyt8HXEPIc9ba61nyx9Zk2qfUo3rtERDC4w1UGzkbb23gv5WXV3KAm6jmcBpBaRaMK-YTd/s1600-h/IM000699.JPG"><img id="BLOGGER_PHOTO_ID_5361859902365750034" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzSbOG6cSMpHIVRDOVSn_TSD6C17-XqxjhdpwKw1GGZr-WIo0ETsdSFeVgSB08-0GfaLBY64eyt8HXEPIc9ba61nyx9Zk2qfUo3rtERDC4w1UGzkbb23gv5WXV3KAm6jmcBpBaRaMK-YTd/s320/IM000699.JPG" border="0" /></a><br />A larger aluminum plate in the new location, ready for the controller to arrive.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizS9YBt-R9bFZkUHQ8dnDn02IZc9-p122C2Lh5PIeQs5ca0RS6vsIQ20U486M6py6X9ToHBz-2UmG41deprXrxzs5bn2f4G75kWacYeA9TGWLH7JHOfMYjQRYdP2uCSqA8AzAkA39KxCmJ/s1600-h/IM000702.JPG"><img id="BLOGGER_PHOTO_ID_5361859479199806658" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizS9YBt-R9bFZkUHQ8dnDn02IZc9-p122C2Lh5PIeQs5ca0RS6vsIQ20U486M6py6X9ToHBz-2UmG41deprXrxzs5bn2f4G75kWacYeA9TGWLH7JHOfMYjQRYdP2uCSqA8AzAkA39KxCmJ/s320/IM000702.JPG" border="0" /></a><br />The controler finally arrives, in time for a gathering of classic and special interest cars that happens every Wednesday in downtown Winnipeg during the summer. Its within range, so I brought my car. With the hood open, the absence of an engine draws quite a bit of interest.DrDonhttp://www.blogger.com/profile/00507851363454428274noreply@blogger.com0tag:blogger.com,1999:blog-2456430570966606735.post-62092976687774075212009-07-02T15:44:00.001-07:002009-07-02T16:30:26.297-07:00Finally, on the road....<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYkcvAzZS9Ah0HUzlXH_2wcRHNeGQlrgyDaOXzYeeyaTTNs7Q_pCAhkTiQmEGxp-PLLAlhm9g2WnyJxqULWal_Xq1W4M5taY3N-32-had3YXR0rKtWiw0OLo4ErssYsiWL0J6PZUq8kQMM/s1600-h/IM000687.JPG"><img style="float:left; margin:0 10px 10px 0;cursor:pointer; cursor:hand;width: 320px; height: 240px;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgYkcvAzZS9Ah0HUzlXH_2wcRHNeGQlrgyDaOXzYeeyaTTNs7Q_pCAhkTiQmEGxp-PLLAlhm9g2WnyJxqULWal_Xq1W4M5taY3N-32-had3YXR0rKtWiw0OLo4ErssYsiWL0J6PZUq8kQMM/s320/IM000687.JPG" border="0" alt=""id="BLOGGER_PHOTO_ID_5353997538411129810" /></a><br />Here is the car after 8 miles running as an ev, with a temporary permit. Still some work to do, like what to do with the old gas filler hole.DrDonhttp://www.blogger.com/profile/00507851363454428274noreply@blogger.com4tag:blogger.com,1999:blog-2456430570966606735.post-72914981717880380042009-06-26T21:23:00.000-07:002009-06-28T21:06:22.402-07:00Getting closer to finishing......<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbCjPtwC2TW2isEXV_hd2FnfaOgF7D51F9xOeecktPoTyyvZrUwIM_NVTY3DEeCj6QVRpyFrnAhsSK2DaVNW01El5hickunZuIWqfAo3QmkbYOd0PMA5IIxyq5oul5g2o4u-FUtGpQCWKE/s1600-h/IM000672.JPG"><img id="BLOGGER_PHOTO_ID_5351860489574666386" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbCjPtwC2TW2isEXV_hd2FnfaOgF7D51F9xOeecktPoTyyvZrUwIM_NVTY3DEeCj6QVRpyFrnAhsSK2DaVNW01El5hickunZuIWqfAo3QmkbYOd0PMA5IIxyq5oul5g2o4u-FUtGpQCWKE/s320/IM000672.JPG" border="0" /></a><br />Connecting up the high voltage (96V) cables to the controler and motor with 2/0 cable.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEmTZRZQ7GGFePESLqOqQhfc8PaSuhKdZyTbTgufsG3IXHx1BHwGMTtcvha7bPEpyjf5X0oIqXpJoB1aEf_ThBiCOdWxpplpTHRm7U1tFZWog_c2YNz0pVwBpndn0LtJKxjPL2zqAVflOK/s1600-h/IM000673.JPG"><img id="BLOGGER_PHOTO_ID_5351859856274243218" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEmTZRZQ7GGFePESLqOqQhfc8PaSuhKdZyTbTgufsG3IXHx1BHwGMTtcvha7bPEpyjf5X0oIqXpJoB1aEf_ThBiCOdWxpplpTHRm7U1tFZWog_c2YNz0pVwBpndn0LtJKxjPL2zqAVflOK/s320/IM000673.JPG" border="0" /></a><br />The front battery box is a modular unit, so it is more or less easy to remove to have access to the motor. It also has the DC/DC inverter, charger, and horns attached to it.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgalYWcfT5jJOrX_bpEqUqkZcUMQWyxxXHTOrNUtKNnyHLjalrKlSZYcMm_PCj0EiqJCEjkd1Mv0TcVZBea0kD533rQVWwS7XC0bz4U05ByBldvuhrhPdc_dAgOP_AbufWFPw4J-TYUhfO6/s1600-h/IM000674.JPG"><img id="BLOGGER_PHOTO_ID_5351860073045289922" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgalYWcfT5jJOrX_bpEqUqkZcUMQWyxxXHTOrNUtKNnyHLjalrKlSZYcMm_PCj0EiqJCEjkd1Mv0TcVZBea0kD533rQVWwS7XC0bz4U05ByBldvuhrhPdc_dAgOP_AbufWFPw4J-TYUhfO6/s320/IM000674.JPG" border="0" /></a><br />The front box mounted in the car.<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHlbHF_m-O3_lvvVS7hZkN7p0ADrrblMH6yleTpPcu0x7DwToh1U07L-BwpGCX1Z0sMPKl-3NckTBVMub7mmudJcDdRP9VrKD4fY9LuF_2YzVadZpduMG6yf8pwloaU7j7pUCuhvA2qTll/s1600-h/IM000676.JPG"><img style="float:left; margin:0 10px 10px 0;cursor:pointer; cursor:hand;width: 320px; height: 240px;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHlbHF_m-O3_lvvVS7hZkN7p0ADrrblMH6yleTpPcu0x7DwToh1U07L-BwpGCX1Z0sMPKl-3NckTBVMub7mmudJcDdRP9VrKD4fY9LuF_2YzVadZpduMG6yf8pwloaU7j7pUCuhvA2qTll/s320/IM000676.JPG" border="0" alt=""id="BLOGGER_PHOTO_ID_5352565135156470002" /></a><br />Batteries installed and connected.<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3JFd3SJalnSCStnuX4n1-NN-8gRHOcf1fht5TqTlZ9RMKY62OEVVwkzxpcFPNhL5VAMbzGGlQ3_P7qkuQblsuui2rJ-v2egLL70gS8P5GMrql5q-9i-hY5UGhDjNt3kMV04J7E6-xN9Aq/s1600-h/IM000678.JPG"><img style="float:left; margin:0 10px 10px 0;cursor:pointer; cursor:hand;width: 320px; height: 240px;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh3JFd3SJalnSCStnuX4n1-NN-8gRHOcf1fht5TqTlZ9RMKY62OEVVwkzxpcFPNhL5VAMbzGGlQ3_P7qkuQblsuui2rJ-v2egLL70gS8P5GMrql5q-9i-hY5UGhDjNt3kMV04J7E6-xN9Aq/s320/IM000678.JPG" border="0" alt=""id="BLOGGER_PHOTO_ID_5352565712158638402" /></a><br />Rear batteries intalled and connected.<br /><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVC2l1IFV8rW3ZZXSHala34DuneuuDaAuDFTPEFZfj6yz43Men03xlZipZpnNQfJkmsG8oTGHb_hc6SNvIz1ltqrdxejtQ4_ye7eHX5uUspm-HmjIKKsMZWuPC4q3_N_gWILzOxiNTXu6w/s1600-h/IM000679.JPG"><img style="float:left; margin:0 10px 10px 0;cursor:pointer; cursor:hand;width: 320px; height: 240px;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgVC2l1IFV8rW3ZZXSHala34DuneuuDaAuDFTPEFZfj6yz43Men03xlZipZpnNQfJkmsG8oTGHb_hc6SNvIz1ltqrdxejtQ4_ye7eHX5uUspm-HmjIKKsMZWuPC4q3_N_gWILzOxiNTXu6w/s320/IM000679.JPG" border="0" alt=""id="BLOGGER_PHOTO_ID_5352564362113988914" /></a><br />Lifting up the rear wheels for a first test of the drive system. <br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNDh0QbDaVsr2p_hGaqC3I7VhNOoBpBlalo1jBPtACS5fHKgJQbtlWfgnOEW5AtXL-memt9Po5W5CXKDF76OqdUScjX2coLDX5M2QZZ-P3VK8Vnc4-KAdzOrfKCzrKl-A1wJ1au1B58R6f/s1600-h/IM000680.JPG"><img style="float:left; margin:0 10px 10px 0;cursor:pointer; cursor:hand;width: 320px; height: 240px;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhNDh0QbDaVsr2p_hGaqC3I7VhNOoBpBlalo1jBPtACS5fHKgJQbtlWfgnOEW5AtXL-memt9Po5W5CXKDF76OqdUScjX2coLDX5M2QZZ-P3VK8Vnc4-KAdzOrfKCzrKl-A1wJ1au1B58R6f/s320/IM000680.JPG" border="0" alt=""id="BLOGGER_PHOTO_ID_5352564040545207778" /></a><br />Progressing to moving the car in the driveway under its own power. Just few more details to get the car reoadworthy, and it should be done.DrDonhttp://www.blogger.com/profile/00507851363454428274noreply@blogger.com0tag:blogger.com,1999:blog-2456430570966606735.post-83928817101348198492009-05-23T14:24:00.000-07:002009-06-10T20:33:41.409-07:00Details, details...<div>Seems like the last 20% of the job is taking 80% of the time.<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJbqGyfpYMG_7wL2WfnzYTCq4c8JifIsuFXfE_rzYUcWvr_A3OgLFkPS-nKWDDvGbNbCrCj5TKnp4-ToZYM37I066VNyVy6nzeCyCUnw3qSoT6nInLidfHBYggAYq-W4jqG8bTc-fcf3zm/s1600-h/IM000611.JPG"><img id="BLOGGER_PHOTO_ID_5339134757889316130" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhJbqGyfpYMG_7wL2WfnzYTCq4c8JifIsuFXfE_rzYUcWvr_A3OgLFkPS-nKWDDvGbNbCrCj5TKnp4-ToZYM37I066VNyVy6nzeCyCUnw3qSoT6nInLidfHBYggAYq-W4jqG8bTc-fcf3zm/s320/IM000611.JPG" border="0" /></a><br />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.<br /><br /><br /><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdE5ovBiePK2506oMCNW6P_aykAQuGWo-TF4_h24sAy80K85u30CAiYeoFLCMAyo2B-y-IIn7BxTX-2oWwL27QPXfRngzAeM1vejz0JRycVImZ8KDYl6dbuRQqwdOtsRP8s0bIkb6ho0ZG/s1600-h/IM000612.JPG"><img id="BLOGGER_PHOTO_ID_5339134895969641218" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjdE5ovBiePK2506oMCNW6P_aykAQuGWo-TF4_h24sAy80K85u30CAiYeoFLCMAyo2B-y-IIn7BxTX-2oWwL27QPXfRngzAeM1vejz0JRycVImZ8KDYl6dbuRQqwdOtsRP8s0bIkb6ho0ZG/s320/IM000612.JPG" border="0" /></a><br /><br />Mounting the controller over the firewall.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhpxOndu5N2puxkRBwesR34cHDBef9gqZFgYRkst5AjQy14PpbZ5rTXH5xnXPTuJGwcQBGHgZVBEap5t45A-7MlZcBuZOJKDU-0NWfLcK_Q_JCiA6e_cGP_xaCO_Q9eLuEWqPL3GQOY8HPW/s1600-h/IM000613.JPG"><img id="BLOGGER_PHOTO_ID_5339135030210705938" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhpxOndu5N2puxkRBwesR34cHDBef9gqZFgYRkst5AjQy14PpbZ5rTXH5xnXPTuJGwcQBGHgZVBEap5t45A-7MlZcBuZOJKDU-0NWfLcK_Q_JCiA6e_cGP_xaCO_Q9eLuEWqPL3GQOY8HPW/s320/IM000613.JPG" border="0" /></a><br />side view showing the spacing of the plates.<br /><br /><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTZM69tG35PU6nAyhf7bYm8ft6LaTf4xcOyfP_GYpQV-SgGHHjii_xJcYnOHSKSOZksm723T4lan3w5FsfayHrK5JP6tMH8CFQAJraj2H7u3xvAnSbKNt7L1P5GDYG6RKZY3jrVrARkVBM/s1600-h/IM000603.JPG"><img id="BLOGGER_PHOTO_ID_5339134267354597042" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 240px; CURSOR: hand; HEIGHT: 320px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjTZM69tG35PU6nAyhf7bYm8ft6LaTf4xcOyfP_GYpQV-SgGHHjii_xJcYnOHSKSOZksm723T4lan3w5FsfayHrK5JP6tMH8CFQAJraj2H7u3xvAnSbKNt7L1P5GDYG6RKZY3jrVrARkVBM/s320/IM000603.JPG" border="0" /></a><br />Accelerator linkage. The pot is contained in a electrical juncton box for extra protection.<br /><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgh2FEvMxVqySDhHqX9OTvxmvNbquFb0O8VrLzh7UtbR4hfn3eCtA7DfVCrNHn0vJmkTOTiYUfWz2LIRV6itUSr8TxEDZUMrTywbjXIcV-Go4LUx0r68f-ZtJeKcNRx60Ie5GOaTb__wtVC/s1600-h/IM000604.JPG"><img id="BLOGGER_PHOTO_ID_5339134406724204978" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgh2FEvMxVqySDhHqX9OTvxmvNbquFb0O8VrLzh7UtbR4hfn3eCtA7DfVCrNHn0vJmkTOTiYUfWz2LIRV6itUSr8TxEDZUMrTywbjXIcV-Go4LUx0r68f-ZtJeKcNRx60Ie5GOaTb__wtVC/s320/IM000604.JPG" border="0" /></a><br />Making a new speedometer faceplate. The old one is yellowed, in MPH, and would not be calibrated because of the new transmission.<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghC0OrS4G5cElOiek-U3oSL8ePN5vY4Xh5mfHSYml6gcTrSExVlPWvQ5on1t7fE-JXpaAoXZ36Z7P4UCjder58gm7Zy9kY7ozaUHo75usfgDdTxI8DduljGq884OlPyDno7Ibc8iQMkvcP/s1600-h/IM000607.JPG"><img id="BLOGGER_PHOTO_ID_5339134569991892434" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEghC0OrS4G5cElOiek-U3oSL8ePN5vY4Xh5mfHSYml6gcTrSExVlPWvQ5on1t7fE-JXpaAoXZ36Z7P4UCjder58gm7Zy9kY7ozaUHo75usfgDdTxI8DduljGq884OlPyDno7Ibc8iQMkvcP/s320/IM000607.JPG" border="0" /></a><br />The dash mostly installed. Although they're irrelevant, the old gages are still there.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHu-UrDkhdp1mC5IADW1UOBRTZ64O7uCT61b8pUl2xbZicrgDO8xqjFTc74vcBc93bch7-Bz3zPb-es2UDlPhqaaAZTQITtcael8kAHHkPIEBBK64jzKY7ednT7OhyphenhyphenqTuLk1YDbYQSyw1l/s1600-h/IM000647.JPG"><img id="BLOGGER_PHOTO_ID_5345903410295973634" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgHu-UrDkhdp1mC5IADW1UOBRTZ64O7uCT61b8pUl2xbZicrgDO8xqjFTc74vcBc93bch7-Bz3zPb-es2UDlPhqaaAZTQITtcael8kAHHkPIEBBK64jzKY7ednT7OhyphenhyphenqTuLk1YDbYQSyw1l/s320/IM000647.JPG" border="0" /></a>The gages for the EV functions are mounted where a radio used to be.<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-rhSRi6nZqa9idAdOUakmylcSvQB3quj75tVoLITNkkUOW5fInWZyjSUzuzWNMsXuIG053pw3kPkQT8sbjg81PwSJYdqghbhPGxCXGCw7IfiHhxNny3FM3WOomAbiapTKFpy142dNia_l/s1600-h/IM000600.JPG"><img id="BLOGGER_PHOTO_ID_5339134075931398850" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-rhSRi6nZqa9idAdOUakmylcSvQB3quj75tVoLITNkkUOW5fInWZyjSUzuzWNMsXuIG053pw3kPkQT8sbjg81PwSJYdqghbhPGxCXGCw7IfiHhxNny3FM3WOomAbiapTKFpy142dNia_l/s320/IM000600.JPG" border="0" /></a><br />Putting on a door </div><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGSFnfoV6XBY5KfoGvDwvJIvkEBX4zg5ym7YfKvkaiTL_3SuLT1d7zCUjgAjT6ceqaTrJqldAO9uzs_tbWRZAfPs3RUgt8BaeSfwxq_agucTLDWQbGNQ-rlGhhyphenhyphenOg9hgLjh1h7eZXT9UPB/s1600-h/IM000653.JPG"><img id="BLOGGER_PHOTO_ID_5345904210227502178" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGSFnfoV6XBY5KfoGvDwvJIvkEBX4zg5ym7YfKvkaiTL_3SuLT1d7zCUjgAjT6ceqaTrJqldAO9uzs_tbWRZAfPs3RUgt8BaeSfwxq_agucTLDWQbGNQ-rlGhhyphenhyphenOg9hgLjh1h7eZXT9UPB/s320/IM000653.JPG" border="0" /></a> lining the rear battery with styrofoam.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdSXUDiCr74-4OvlPnaaVhqBaL8HyhlEb6vSSg25VFZEARQkNfrm4RK8jQZyZm66VD3hYVa6PJ3Ov_tVXFL_6rhumvTXlWeJT6m6mNIbDbvepv-LWwFFPpoE1Fsi6pnwpxdJ8XNUQPIl1K/s1600-h/IM000662.JPG"><img id="BLOGGER_PHOTO_ID_5345904809161061586" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdSXUDiCr74-4OvlPnaaVhqBaL8HyhlEb6vSSg25VFZEARQkNfrm4RK8jQZyZm66VD3hYVa6PJ3Ov_tVXFL_6rhumvTXlWeJT6m6mNIbDbvepv-LWwFFPpoE1Fsi6pnwpxdJ8XNUQPIl1K/s320/IM000662.JPG" border="0" /></a>Installing PVC conduit for the the high voltage cables going to the back battery box.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPAbC0jnHXSKTZ5RQIgHYuTFobNfvSTB44UhY9nrCtUgyXckxuFGbecAwBdOnuRSkOp764GuBouiaYsu7O_d7Gc0G1hPHoROHxmaHUco90CUebQIwqUnCESXjsHOW4q8Bv3rYkBIeN-gKV/s1600-h/IM000659.JPG"><img id="BLOGGER_PHOTO_ID_5345904651395950546" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiPAbC0jnHXSKTZ5RQIgHYuTFobNfvSTB44UhY9nrCtUgyXckxuFGbecAwBdOnuRSkOp764GuBouiaYsu7O_d7Gc0G1hPHoROHxmaHUco90CUebQIwqUnCESXjsHOW4q8Bv3rYkBIeN-gKV/s320/IM000659.JPG" border="0" /></a><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-yrMjJFsQA7xKTndDUNZUIeKePDScUOepKFmg8ULNKNpczHSsQtLKMUNHmHTiyyoPHXdoBgrXadmhLn6DUbr0QnyLPuJIV4cdEyqIXcOXZWOnamSYIXZM6IrgXYJpR2BZRpKW-0Fu2Qq8/s1600-h/IM000664.JPG"><img id="BLOGGER_PHOTO_ID_5345905402648679042" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi-yrMjJFsQA7xKTndDUNZUIeKePDScUOepKFmg8ULNKNpczHSsQtLKMUNHmHTiyyoPHXdoBgrXadmhLn6DUbr0QnyLPuJIV4cdEyqIXcOXZWOnamSYIXZM6IrgXYJpR2BZRpKW-0Fu2Qq8/s320/IM000664.JPG" border="0" /></a> Pushing the cable through the conduit at the back battery box. Baby powder makes it slide in much more easily.<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcuQn-xPA8BGbVFHQ2Pdw-cQJFAFbxRphpHXzuFwTYRdDPapnJ9qFAhUlXPsp93RrVbaxx97I2vmYoErlsfp-_PJweoS96Q57S7Stgn-uo25XbEXsOqhKzYFN6Q3P4R0_oLN0WT3-Wvd0h/s1600-h/IM000648.JPG"><img id="BLOGGER_PHOTO_ID_5345906263811885346" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhcuQn-xPA8BGbVFHQ2Pdw-cQJFAFbxRphpHXzuFwTYRdDPapnJ9qFAhUlXPsp93RrVbaxx97I2vmYoErlsfp-_PJweoS96Q57S7Stgn-uo25XbEXsOqhKzYFN6Q3P4R0_oLN0WT3-Wvd0h/s320/IM000648.JPG" border="0" /></a><br />Running new wiring for the low voltage side.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiH1FQ0zFz7s1WEGFFnLp3IyTi0g_qKB8qgzCKJRZOHvRV6gQ4zRxRdZyIFryjzyczV64M2QYoY36BUPol2zUVSTSOsoWEg1MUKHCBYw8mn1OvIcQOd8cNoWwm2aZFuuuzXUgS-Ud1DHE7d/s1600-h/IM000665.JPG"><img id="BLOGGER_PHOTO_ID_5345906696664160818" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiH1FQ0zFz7s1WEGFFnLp3IyTi0g_qKB8qgzCKJRZOHvRV6gQ4zRxRdZyIFryjzyczV64M2QYoY36BUPol2zUVSTSOsoWEg1MUKHCBYw8mn1OvIcQOd8cNoWwm2aZFuuuzXUgS-Ud1DHE7d/s320/IM000665.JPG" border="0" /></a>Laying out the control components on a board.DrDonhttp://www.blogger.com/profile/00507851363454428274noreply@blogger.com3tag:blogger.com,1999:blog-2456430570966606735.post-58769703479715351752009-05-01T21:27:00.000-07:002009-05-24T21:52:19.581-07:00Getting closer to a car that starts and stops<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEifd5mz8-zTkAQal-01yFu2h3rPZO7NsJLiq2JxlRw8O9RYC4_KUHZJfJpI0maphKoPPPnweIYAAGJg7Vf8sq0VSAaw6rV64pKqDN1f5C9Biv5Y0kuYfQK99PjtH9UZbb3eIB3gcJ8Z3O36/s1600-h/IM000547.JPG"><img id="BLOGGER_PHOTO_ID_5331083095226871090" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEifd5mz8-zTkAQal-01yFu2h3rPZO7NsJLiq2JxlRw8O9RYC4_KUHZJfJpI0maphKoPPPnweIYAAGJg7Vf8sq0VSAaw6rV64pKqDN1f5C9Biv5Y0kuYfQK99PjtH9UZbb3eIB3gcJ8Z3O36/s320/IM000547.JPG" border="0" /></a><br />Making a modified "dog house" to fit the transmission, using part of the original cover and sheet metal from an old 286 IBM PC.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKC4_51qtW7L1Oo-kKgzP0YP05inpqq8lwaZPsX39Hn4An5v2HyFCsqnVROkLX4DwNqleTkjaxKGnnppm634PE0raB1eZFVoTLsxkdrEgKPumgNuZRCS0qrig0E_kqHFP575lt0K9C8H3E/s1600-h/IM000546.JPG"><img id="BLOGGER_PHOTO_ID_5331082914697711282" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKC4_51qtW7L1Oo-kKgzP0YP05inpqq8lwaZPsX39Hn4An5v2HyFCsqnVROkLX4DwNqleTkjaxKGnnppm634PE0raB1eZFVoTLsxkdrEgKPumgNuZRCS0qrig0E_kqHFP575lt0K9C8H3E/s320/IM000546.JPG" border="0" /></a><br />Mounts to hold the adapter plate to the frame.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEZN7KGs0jMx704bmVVwe3U3KFLCGEvxWWjYKFjKiymD9uo3w2TGYXoArSqbexncaD6WsJdmRQqRm-1pJVDvDaUNZnNK5jJf1mCHAsWKayWNMLVHDWyWEB_llmEalC_GPDlB9uQ2KgIwbE/s1600-h/IM000552.JPG"><img id="BLOGGER_PHOTO_ID_5331082644908089746" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhEZN7KGs0jMx704bmVVwe3U3KFLCGEvxWWjYKFjKiymD9uo3w2TGYXoArSqbexncaD6WsJdmRQqRm-1pJVDvDaUNZnNK5jJf1mCHAsWKayWNMLVHDWyWEB_llmEalC_GPDlB9uQ2KgIwbE/s320/IM000552.JPG" border="0" /></a><br />Installation of the firewall-mounted, more modern, master brake cylinder. The original was frame mounted under the driver seat.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgabDGFzu5ejOX8R7Jhodqcr59ARzQbGWC-k-MlyqohkodFoX-w0SnKgBqDVK6GqlgKrc8GsDBHtApaZ-yDbGRY1dOXF2Eyc5YJgtbVhQ92WPp8Mf7XcicYRdpsU7GuJ09_c7c_H_G1ygDh/s1600-h/IM000570.JPG"><img id="BLOGGER_PHOTO_ID_5331082356699445266" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgabDGFzu5ejOX8R7Jhodqcr59ARzQbGWC-k-MlyqohkodFoX-w0SnKgBqDVK6GqlgKrc8GsDBHtApaZ-yDbGRY1dOXF2Eyc5YJgtbVhQ92WPp8Mf7XcicYRdpsU7GuJ09_c7c_H_G1ygDh/s320/IM000570.JPG" border="0" /></a><br />The temperature is warming up enough to do some painting, and the car is slowly becoming more monochromatic.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiF8y8fsHIGTsvIwfw03zzJrFEZSFZWO2jSRtLhH15ffM5FTjAVnms5WYd7mHxT7pdJ9VFpkNf4lKzXHk2xhtCBx9tIqeVym1ilEqQcNf5A8z0upnz3VXoWEMI_RUhKLoUeMZ5Jd_oclHTg/s1600-h/IM000582.JPG"><img id="BLOGGER_PHOTO_ID_5331082171486609650" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiF8y8fsHIGTsvIwfw03zzJrFEZSFZWO2jSRtLhH15ffM5FTjAVnms5WYd7mHxT7pdJ9VFpkNf4lKzXHk2xhtCBx9tIqeVym1ilEqQcNf5A8z0upnz3VXoWEMI_RUhKLoUeMZ5Jd_oclHTg/s320/IM000582.JPG" border="0" /></a><br />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.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7IM3b63JYrMiWnGJ58NrVLj_-3gUx0aiU8ToenEV2Icu5KrU5vbOI0npZVNJPtbzMliapsKoVRSFllTLARsKxj3fzKPUDfu_szNhp2Bzti2863touSINEQwYZXkeilzs2tvfkW9VamKUD/s1600-h/IM000579.JPG"><img id="BLOGGER_PHOTO_ID_5331088831444333042" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7IM3b63JYrMiWnGJ58NrVLj_-3gUx0aiU8ToenEV2Icu5KrU5vbOI0npZVNJPtbzMliapsKoVRSFllTLARsKxj3fzKPUDfu_szNhp2Bzti2863touSINEQwYZXkeilzs2tvfkW9VamKUD/s320/IM000579.JPG" border="0" /></a><br />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.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwAiA6cnShfSJo87z4wq2RUYbkpqQGiJanqonQEToS2V58vwD7Dc3GFZUCseu4zQoDPHD6FexnfG7EtIqT1I93_Km1efgU5tkBgX6goSkpxr0sEGeMJtmpn1v9IzNcvjZ1bxKy-FMKQZ3_/s1600-h/IM000586.JPG"><img id="BLOGGER_PHOTO_ID_5331081696736156002" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiwAiA6cnShfSJo87z4wq2RUYbkpqQGiJanqonQEToS2V58vwD7Dc3GFZUCseu4zQoDPHD6FexnfG7EtIqT1I93_Km1efgU5tkBgX6goSkpxr0sEGeMJtmpn1v9IzNcvjZ1bxKy-FMKQZ3_/s320/IM000586.JPG" border="0" /></a><br />Looking inside the bell housing at the coupler.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhU9-fVDtvgGvh4RwOdG3Og17k47KEv4wtWYUFkCuq89-f7UWUmBl3rMt1sGBRralmm6HxoCJl6mcPXEotOYz3ULiG5JzqvtXiGZnCqX-JHfZvfYqzEFHp0eMGy3w7R-uGsHLFPcRb_4DZX/s1600-h/IM000587.JPG"><img id="BLOGGER_PHOTO_ID_5331081461798329314" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhU9-fVDtvgGvh4RwOdG3Og17k47KEv4wtWYUFkCuq89-f7UWUmBl3rMt1sGBRralmm6HxoCJl6mcPXEotOYz3ULiG5JzqvtXiGZnCqX-JHfZvfYqzEFHp0eMGy3w7R-uGsHLFPcRb_4DZX/s320/IM000587.JPG" border="0" /></a><br />the motor and transmission assembled. <br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQzIvUqUP1cenaZRyy_ORFvzpJ0teA41ZfyunZFredfVnVAcwcSXf1KgJbuAbObYBBOEOa3Qwwxew4yNyXxdE3yFfetXLy2iJ-Hk9ZdQJ5ZTrX-pG1HXeuM8oxKJWVso-x6KatB9vysF3k/s1600-h/IM000593.JPG"><img style="float:left; margin:0 10px 10px 0;cursor:pointer; cursor:hand;width: 320px; height: 240px;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQzIvUqUP1cenaZRyy_ORFvzpJ0teA41ZfyunZFredfVnVAcwcSXf1KgJbuAbObYBBOEOa3Qwwxew4yNyXxdE3yFfetXLy2iJ-Hk9ZdQJ5ZTrX-pG1HXeuM8oxKJWVso-x6KatB9vysF3k/s320/IM000593.JPG" border="0" alt=""id="BLOGGER_PHOTO_ID_5332171533141252834" /></a><br />Lifting the motor into place.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCbbeNNydN2hKWtwbDl2s50G5ToEXoR1-LZip_u-gW6UcYG45AZ9D-kDWSjmc1-GT3Agg9pn8FxmuKf1FhNqfGws62omGTqHwsOvre5iyRRoKeAaQ3WfkwicpbejI8gE1MEwXXcrJ916dD/s1600-h/IM000592.JPG"><img style="float:left; margin:0 10px 10px 0;cursor:pointer; cursor:hand;width: 320px; height: 240px;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiCbbeNNydN2hKWtwbDl2s50G5ToEXoR1-LZip_u-gW6UcYG45AZ9D-kDWSjmc1-GT3Agg9pn8FxmuKf1FhNqfGws62omGTqHwsOvre5iyRRoKeAaQ3WfkwicpbejI8gE1MEwXXcrJ916dD/s320/IM000592.JPG" border="0" alt=""id="BLOGGER_PHOTO_ID_5332171855110070770" /></a><br />Connecting the driveshaft.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbgL8xR4yC58c5oE2jzNscWDHB1eEkiyq1P7sNmKRcPmwIyh0ZS2Eee_gAE7K-t5e2WqO73rQjo0RJdId_TDIOWLdDOdrt5KLRGgfHJouofhXV5EEnyBDoO_ws5aRVDKywZ5jKWwJHMxNA/s1600-h/IM000594.JPG"><img style="float:left; margin:0 10px 10px 0;cursor:pointer; cursor:hand;width: 320px; height: 240px;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjbgL8xR4yC58c5oE2jzNscWDHB1eEkiyq1P7sNmKRcPmwIyh0ZS2Eee_gAE7K-t5e2WqO73rQjo0RJdId_TDIOWLdDOdrt5KLRGgfHJouofhXV5EEnyBDoO_ws5aRVDKywZ5jKWwJHMxNA/s320/IM000594.JPG" border="0" alt=""id="BLOGGER_PHOTO_ID_5332172224604348306" /></a><br />Assembling the adapter plate bracket.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitKZGx1Xa32oOQruNUaJeUA3U9wJLn5zNCNjwAWpQ7H3VptmuutFO_4FG-1losZw9Wp-rKbjft8AtSWCHjf7t_BBdFYHHrjN9SxYDvcOZUW2pJ2r74b1RlNASFZVys21pnWWu4uQJQLpO0/s1600-h/IM000598.JPG"><img style="float:left; margin:0 10px 10px 0;cursor:pointer; cursor:hand;width: 320px; height: 240px;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEitKZGx1Xa32oOQruNUaJeUA3U9wJLn5zNCNjwAWpQ7H3VptmuutFO_4FG-1losZw9Wp-rKbjft8AtSWCHjf7t_BBdFYHHrjN9SxYDvcOZUW2pJ2r74b1RlNASFZVys21pnWWu4uQJQLpO0/s320/IM000598.JPG" border="0" alt=""id="BLOGGER_PHOTO_ID_5332172512997838658" /></a><br />Anxious to see the parts turning, I try running the whole drive train, with rear tires off the ground, with a 12V battery.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHEoPf4pYotRcZrgGRsyDkcZcZSvEV4yTDVKiG27Wj9s6HHWmQI7aonUz5gT4MeuTJoQ1LelkbC1pcTOhAHs7FV7FbOFCiwfi3LPkCJwM0UrO3jo8sOzpNibrX3aCIcPOOndVDP7zwwx5H/s1600-h/IM000605.JPG"><img style="float:left; margin:0 10px 10px 0;cursor:pointer; cursor:hand;width: 320px; height: 240px;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiHEoPf4pYotRcZrgGRsyDkcZcZSvEV4yTDVKiG27Wj9s6HHWmQI7aonUz5gT4MeuTJoQ1LelkbC1pcTOhAHs7FV7FbOFCiwfi3LPkCJwM0UrO3jo8sOzpNibrX3aCIcPOOndVDP7zwwx5H/s320/IM000605.JPG" border="0" alt=""id="BLOGGER_PHOTO_ID_5339619235393026418" /></a><br />The addition of a front bracket to support the back of the motor.DrDonhttp://www.blogger.com/profile/00507851363454428274noreply@blogger.com2tag:blogger.com,1999:blog-2456430570966606735.post-75785763208935251992009-02-15T21:00:00.000-08:002009-02-22T20:32:17.250-08:00Laying out the underhood area, and finishing the heater.Time to start figuring out how all the parts will fit under the hood. The pizza boxes I've been saving up will prove useful here.<br /><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjV72VhmrFy0M-n5yL-05k5_KjkcPlX8lNfvmlGtP18NiayOWIDJhhTSe6r9fcEDUz730aLD_84zr1UMZOg0cTgexQMPai3Qho4wLN7K5F-9Cj_CBuf_dH4EE38SS8SB6goEmLZRSmPw3VZ/s1600-h/IM000506.JPG"><img id="BLOGGER_PHOTO_ID_5303258948675659858" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 240px; CURSOR: hand; HEIGHT: 320px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjV72VhmrFy0M-n5yL-05k5_KjkcPlX8lNfvmlGtP18NiayOWIDJhhTSe6r9fcEDUz730aLD_84zr1UMZOg0cTgexQMPai3Qho4wLN7K5F-9Cj_CBuf_dH4EE38SS8SB6goEmLZRSmPw3VZ/s320/IM000506.JPG" border="0" /></a><br />Thus I started putting in the steering column, emergency brake, firewall mounted brake pedal, transmission... <br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrG3dJfSPjTNYS9ys4adz8Q_qkt2VKocgeK57c4FZ2sidZm0ZFW6J9g3KK6t-y82mH97ZFaMu9csoYAMLQp82tV7oeJn3r-QzZpllBF-fXXNJR-fKlst3HRCkvqPez3QWfdGSpCVW4SvZC/s1600-h/IM000516.JPG"><img id="BLOGGER_PHOTO_ID_5303258489554181714" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhrG3dJfSPjTNYS9ys4adz8Q_qkt2VKocgeK57c4FZ2sidZm0ZFW6J9g3KK6t-y82mH97ZFaMu9csoYAMLQp82tV7oeJn3r-QzZpllBF-fXXNJR-fKlst3HRCkvqPez3QWfdGSpCVW4SvZC/s320/IM000516.JPG" border="0" /></a><br />Here I have a cardboard model of the 8" motor, as I don't have my real one yet. There is not much room for anything larger, so while I thought a of going with a 9" motor to get more performance, the option was not really there.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQB4wdFxaQ-SO7R9nLRJLHBTu3j4MH5Q_kgqU9CgB_o1ICo5agk2QF5bYJeWCgSOumc_EZeCQ6Gmbm7w_df14DQcbc9UCEiGoDIlD_pcHZV4nhwoIeOHXbeyBzUXVL02BsOG2ccn_rShKe/s1600-h/IM000526.JPG"><img id="BLOGGER_PHOTO_ID_5303258295093069522" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjQB4wdFxaQ-SO7R9nLRJLHBTu3j4MH5Q_kgqU9CgB_o1ICo5agk2QF5bYJeWCgSOumc_EZeCQ6Gmbm7w_df14DQcbc9UCEiGoDIlD_pcHZV4nhwoIeOHXbeyBzUXVL02BsOG2ccn_rShKe/s320/IM000526.JPG" border="0" /></a><br />A criterion of my design is to group all the batteries together in an insulated box, as done for the rear batteries, so I really can't stick my batteries here and there wherever there's a spot, as seen in some conversions. Here I'm trying out simple box arrangement that would hold 4 batteries in a 2x2 arrangement. It doesnt fit that well and doesn't provide clearance in critical areas.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh79VA9oWABYKk_EtNQucKAfGhTw0DoCsBTpLs5csev0Vznag6g1r57lzpAgwxQgbujqIT2XQw-tlFF1ko5inFUrMRtqAv1HHqHVQgGEZAiIrRFPmNtIsr3C155WmoReZxZl_kNvPohAKjA/s1600-h/IM000517.JPG"><img id="BLOGGER_PHOTO_ID_5303257999370696930" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh79VA9oWABYKk_EtNQucKAfGhTw0DoCsBTpLs5csev0Vznag6g1r57lzpAgwxQgbujqIT2XQw-tlFF1ko5inFUrMRtqAv1HHqHVQgGEZAiIrRFPmNtIsr3C155WmoReZxZl_kNvPohAKjA/s320/IM000517.JPG" border="0" /></a><br />A second arrangement. Clearance is a bit better, however the batteries sit a bit higher up.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjkTsVfgROOoOlMNyXZUFIZRVfpbZ98eMdlARNUZyYVJu7rSDFBeBxig3y4hbZE5o-DUbxlUNlTql85fCVqCwNNi2mHRKxqOmuP30m5Q-APnbTnXLwkDMd_asEUDP5u5cricVgb4Aw719Xn/s1600-h/IM000522.JPG"><img id="BLOGGER_PHOTO_ID_5303258156886339186" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjkTsVfgROOoOlMNyXZUFIZRVfpbZ98eMdlARNUZyYVJu7rSDFBeBxig3y4hbZE5o-DUbxlUNlTql85fCVqCwNNi2mHRKxqOmuP30m5Q-APnbTnXLwkDMd_asEUDP5u5cricVgb4Aw719Xn/s320/IM000522.JPG" border="0" /></a><br />This is a different arrangement that will make more room about the brake linkage components. This will require hammering back the wheel wells a few inches in the front, however, here the batteries will sit lower. This layout should work. <br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg562eY8_2s8HAvJPORpyaOpydrMsfCDmyP2KJcbDLyohBy69GyRzan8OrMibgFB5o_0jgVi0J4PkHQ0qS6RrvcKD9P2KKBj71j0RBZ8AqVJNf3L0cxMz0qtCv4m0HLEPMMtkS7ZYL4v05B/s1600-h/IM000530.JPG"><img style="float:left; margin:0 10px 10px 0;cursor:pointer; cursor:hand;width: 320px; height: 240px;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg562eY8_2s8HAvJPORpyaOpydrMsfCDmyP2KJcbDLyohBy69GyRzan8OrMibgFB5o_0jgVi0J4PkHQ0qS6RrvcKD9P2KKBj71j0RBZ8AqVJNf3L0cxMz0qtCv4m0HLEPMMtkS7ZYL4v05B/s320/IM000530.JPG" border="0" alt=""id="BLOGGER_PHOTO_ID_5305836686204107330" /></a><br />The start of the front battery box(es).<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxetAnEovkFJP5szlev8_tZRVe3vstfgFkabWxf9DYW9P25usqmCJOJXht1ryugZhDV4DX78u7pk2h_nNF-bXa4OabCrBjUNsALkaJ34kgL2taVkpKDaAgW9UukilJ4UAZt9qUv8_TASh0/s1600-h/IM000511.JPG"><img id="BLOGGER_PHOTO_ID_5303257872175066578" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxetAnEovkFJP5szlev8_tZRVe3vstfgFkabWxf9DYW9P25usqmCJOJXht1ryugZhDV4DX78u7pk2h_nNF-bXa4OabCrBjUNsALkaJ34kgL2taVkpKDaAgW9UukilJ4UAZt9qUv8_TASh0/s320/IM000511.JPG" border="0" /></a><br />Back to the heater. There is quite a difference between the old heater core and the ceramic element taken from a $25 heater that will replace it.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLBiKL0_urBG0rpQg8k0cYwm1ncNqnnDNyCm9DPn93-gSkOtxNIUyQ-87WRNoJha5sTl27c87ciHQK8hEogKFU0sey1470efaDgTW7paRYWfzAIxjyd97A_hxGVmwTbN-ezejN_XQB8sF_/s1600-h/IM000512.JPG"><img id="BLOGGER_PHOTO_ID_5303257738816149154" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLBiKL0_urBG0rpQg8k0cYwm1ncNqnnDNyCm9DPn93-gSkOtxNIUyQ-87WRNoJha5sTl27c87ciHQK8hEogKFU0sey1470efaDgTW7paRYWfzAIxjyd97A_hxGVmwTbN-ezejN_XQB8sF_/s320/IM000512.JPG" border="0" /></a><br />Making a metal shroud to accomodate the smaller size. I knew the cover from the old BetaMax VCR would come in handy some day.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihZbqPuA0Ezx9lCBAG64402fqu8j9jaW6m89Vh2Kh69xR_vaelU6pM5nY8NspuM6dKt-AD1xCu45ZY2ei4xdIT08HVFeZNYgw3bn_HJsSQGL2xRXEPnF3yfJ3K8nCwJEOZbzD13Cn1jdpH/s1600-h/IM000514.JPG"><img id="BLOGGER_PHOTO_ID_5303257565069127922" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEihZbqPuA0Ezx9lCBAG64402fqu8j9jaW6m89Vh2Kh69xR_vaelU6pM5nY8NspuM6dKt-AD1xCu45ZY2ei4xdIT08HVFeZNYgw3bn_HJsSQGL2xRXEPnF3yfJ3K8nCwJEOZbzD13Cn1jdpH/s320/IM000514.JPG" border="0" /></a><br />The completed shroud.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhHNJvIz8yhPsiGfyImZbB_qVh_jTe7HnmgUcwZOUvUVSdAXM4AQX-MTU1bfNVwUJOQHiqW9OIy8GKUBxOvRlIVnlsRfuXy7TI0sy0tcWqXoWD9i1ysNfLYZZcAtDXyIYUzWYGqDa6zmS3u/s1600-h/IM000515.JPG"><img id="BLOGGER_PHOTO_ID_5303257401378814050" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhHNJvIz8yhPsiGfyImZbB_qVh_jTe7HnmgUcwZOUvUVSdAXM4AQX-MTU1bfNVwUJOQHiqW9OIy8GKUBxOvRlIVnlsRfuXy7TI0sy0tcWqXoWD9i1ysNfLYZZcAtDXyIYUzWYGqDa6zmS3u/s320/IM000515.JPG" border="0" /></a><br />The element mounted on the shroud.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAWDe_DzWIS9PL9fOaPCJrepWvK-npgqDQThe4Va023y6vp3YzI7xfI8jIM4RQRTyktweekj0T15h8ooe4QhC47VV1YJyONaKwQbPF9pmgLbpY_Y0Q93NQnLRq9vr1Y4uMGRik4AeHMqgZ/s1600-h/IM000528.JPG"><img id="BLOGGER_PHOTO_ID_5303257256790664882" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiAWDe_DzWIS9PL9fOaPCJrepWvK-npgqDQThe4Va023y6vp3YzI7xfI8jIM4RQRTyktweekj0T15h8ooe4QhC47VV1YJyONaKwQbPF9pmgLbpY_Y0Q93NQnLRq9vr1Y4uMGRik4AeHMqgZ/s320/IM000528.JPG" border="0" /></a><br />more parts assembled...<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhv7p9I4zLg452AmSyqx7Zr5B4tDQ-bAaoa7VA7s_US_GND9yELYVr1BGlMptc1Rfi2FSNOkpKU2-b6T3EZhzBHdSPq4x8DQs8EP7YYVIbZYIqpx0Aflo-XUZYiCsmaU-WGgiaxlsKAL4Qa/s1600-h/IM000529.JPG"><img id="BLOGGER_PHOTO_ID_5303257045437652978" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhv7p9I4zLg452AmSyqx7Zr5B4tDQ-bAaoa7VA7s_US_GND9yELYVr1BGlMptc1Rfi2FSNOkpKU2-b6T3EZhzBHdSPq4x8DQs8EP7YYVIbZYIqpx0Aflo-XUZYiCsmaU-WGgiaxlsKAL4Qa/s320/IM000529.JPG" border="0" /></a><br />And the finished heater. </div>DrDonhttp://www.blogger.com/profile/00507851363454428274noreply@blogger.com0tag:blogger.com,1999:blog-2456430570966606735.post-58076722867203759212009-02-08T13:03:00.000-08:002009-02-08T13:32:31.688-08:00Making the first battery box....<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQek67FIgBGSiSqLRQKRPpgdqCgt7ji3lR6stnczdHxy_NETDUscIlXYTxhDv_g-dxeVjMTCNggmAWdQHBVgcjqgILES86vXOSUb5EerlTitXn2jEwHHiin3baSww9oyAdyIaGAmOUeM3J/s1600-h/IM000495.JPG"><img style="float:left; margin:0 10px 10px 0;cursor:pointer; cursor:hand;width: 320px; height: 240px;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgQek67FIgBGSiSqLRQKRPpgdqCgt7ji3lR6stnczdHxy_NETDUscIlXYTxhDv_g-dxeVjMTCNggmAWdQHBVgcjqgILES86vXOSUb5EerlTitXn2jEwHHiin3baSww9oyAdyIaGAmOUeM3J/s320/IM000495.JPG" border="0" alt=""id="BLOGGER_PHOTO_ID_5300537129006904306" /></a><br />This is the steel frame for the rear battery box, made of slotted angle iron. It will hold four 12V batteries (Trojan 1275 flooded lead acid golf cart batteries) the walls will be made of plywood and will have a 1" styrofoam lining for insulation. (the top part of the frame has not yet been assembled in this photo)<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLwo7Teuq4ht3bKPHnycLRUxvsL0FaBh5bMWTAtOKyWsYDSCG6_D2q-s96uVUMh3zk8i0rbs96uOqy6GCyK4rSF_CWvHTUoXq6sRlJ79QekdCgUGsIHJcvgahUqlolRjzamS6cqQExRTTh/s1600-h/IM000494.JPG"><img style="float:left; margin:0 10px 10px 0;cursor:pointer; cursor:hand;width: 320px; height: 240px;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgLwo7Teuq4ht3bKPHnycLRUxvsL0FaBh5bMWTAtOKyWsYDSCG6_D2q-s96uVUMh3zk8i0rbs96uOqy6GCyK4rSF_CWvHTUoXq6sRlJ79QekdCgUGsIHJcvgahUqlolRjzamS6cqQExRTTh/s320/IM000494.JPG" border="0" alt=""id="BLOGGER_PHOTO_ID_5300536389476157634" /></a><br />The original gas tank also served as part of the trunk floor, so its removal leaves a hole in the trunk, but its not large enough for the battery box.<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivCcR8XAVN-c3ikiZ3T_Wxtn7rl3Cgtwwfrgnwj2Fjf1L_xWrmbuWefuebdjEkmeGWtoWeLHtvi_YVGQqBjmObIqHCx53PiLPpgwQfMJS6LZn1fLVR637IJAOthrP7Hej1Z2znqdqSwdmE/s1600-h/IM000499.JPG"><img style="float:left; margin:0 10px 10px 0;cursor:pointer; cursor:hand;width: 320px; height: 240px;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEivCcR8XAVN-c3ikiZ3T_Wxtn7rl3Cgtwwfrgnwj2Fjf1L_xWrmbuWefuebdjEkmeGWtoWeLHtvi_YVGQqBjmObIqHCx53PiLPpgwQfMJS6LZn1fLVR637IJAOthrP7Hej1Z2znqdqSwdmE/s320/IM000499.JPG" border="0" alt=""id="BLOGGER_PHOTO_ID_5300535945236076162" /></a><br />After elarging the hole.<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSxR_4b3gf99mjux0SbJAxyBhyeGJV3CVVSlz7P7TDrQx5AwdK8iH1Wdtl7I-O8bNAEE7zABumpbmzepzyCgGcwz5uw5evhyl49ufaP6tmdDGdubnqhFaQkDKwcebQsOkJbJYLT1JtkFI-/s1600-h/IM000500.JPG"><img style="float:left; margin:0 10px 10px 0;cursor:pointer; cursor:hand;width: 320px; height: 240px;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgSxR_4b3gf99mjux0SbJAxyBhyeGJV3CVVSlz7P7TDrQx5AwdK8iH1Wdtl7I-O8bNAEE7zABumpbmzepzyCgGcwz5uw5evhyl49ufaP6tmdDGdubnqhFaQkDKwcebQsOkJbJYLT1JtkFI-/s320/IM000500.JPG" border="0" alt=""id="BLOGGER_PHOTO_ID_5300535477395819186" /></a><br /><br />Its a tight fit, but the box goes in.<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxcplS4tdSFGg5zozjkf4PPlqdvfXhW3zX9fBb3jpktYOps2yXABcqCZDz5-wBwYMG7Eq5uZU6VG3YZZlXrG7Wmkiu-vM2IS2hcjlzOfSAmfkI5bGs_dLV883EGAA9oyOepPkcSXTkvoOa/s1600-h/IM000496.JPG"><img style="float:left; margin:0 10px 10px 0;cursor:pointer; cursor:hand;width: 320px; height: 240px;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhxcplS4tdSFGg5zozjkf4PPlqdvfXhW3zX9fBb3jpktYOps2yXABcqCZDz5-wBwYMG7Eq5uZU6VG3YZZlXrG7Wmkiu-vM2IS2hcjlzOfSAmfkI5bGs_dLV883EGAA9oyOepPkcSXTkvoOa/s320/IM000496.JPG" border="0" alt=""id="BLOGGER_PHOTO_ID_5300538098520045154" /></a><br />Next will be the front battery box that will hold another 4 batteries. With tigher space constraints, and other parts in the way like brake mechanisms and a steering column, this will be more of a challenge. Using cardboard mockups of the batteries is useful in trying different layouts.DrDonhttp://www.blogger.com/profile/00507851363454428274noreply@blogger.com0tag:blogger.com,1999:blog-2456430570966606735.post-81042771505040317322009-01-17T17:36:00.000-08:002009-02-08T13:02:47.625-08:00Drive train and painting<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUGKQuXpK0beHEjdFryKSEmlQ_tCT_U3zzCRLxi9GA8VJ-I9Kjrj407MroWgJL606v4UHM4rqZK-oRZ9FvzMMoi4zvWVVqD4OF1Vl9LZ0nzbs4j1FHuQkm9yoXjcv6x88L8pfR7wqUQAAw/s1600-h/IM000453.JPG"><img id="BLOGGER_PHOTO_ID_5292442890427585698" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUGKQuXpK0beHEjdFryKSEmlQ_tCT_U3zzCRLxi9GA8VJ-I9Kjrj407MroWgJL606v4UHM4rqZK-oRZ9FvzMMoi4zvWVVqD4OF1Vl9LZ0nzbs4j1FHuQkm9yoXjcv6x88L8pfR7wqUQAAw/s320/IM000453.JPG" border="0" /></a><br />A good friend of mine has been kind enough to weld the pieces of my slip yolk together (see previous posts to how these were made). A good solid weld was achieved without any distortion of the universal joint arms.<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpjeNENk2hONlJr0xYD3QYtJH6N8tOqUSSgx1a4cK3HJfKsYgrowI1kjXH6FUjvu6_Uh3l7cmi3FTNsh-SUX0GlyOAcBX-Gwsf3Fg3l-QuJgdxJEz5qMt1C6U_GHthXYsg1OnBvja6WXhN/s1600-h/IM000455.JPG"><img id="BLOGGER_PHOTO_ID_5292442598900633618" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjpjeNENk2hONlJr0xYD3QYtJH6N8tOqUSSgx1a4cK3HJfKsYgrowI1kjXH6FUjvu6_Uh3l7cmi3FTNsh-SUX0GlyOAcBX-Gwsf3Fg3l-QuJgdxJEz5qMt1C6U_GHthXYsg1OnBvja6WXhN/s320/IM000455.JPG" border="0" /></a><br />This is the slip yolk after a bit of grinding of the weld bead as it spun on the lathe, which should help to keep it balanced.<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7Tcuwht_cOxOaeFyT0m4l7t9dng62EVpndvo8I9MulMiNelh-u7-nqZUb6G5dyU3BnnjOT4uj168k-Zk_tFdBk68K5M8XfyOT3kRf_CoJHLrGQ9gjCw979lU6LEJ07lon9mxBL_PwzaKI/s1600-h/IM000459.JPG"><img id="BLOGGER_PHOTO_ID_5295834478170157954" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj7Tcuwht_cOxOaeFyT0m4l7t9dng62EVpndvo8I9MulMiNelh-u7-nqZUb6G5dyU3BnnjOT4uj168k-Zk_tFdBk68K5M8XfyOT3kRf_CoJHLrGQ9gjCw979lU6LEJ07lon9mxBL_PwzaKI/s320/IM000459.JPG" border="0" /></a><br />The slip yoke connected to the original prop shaft, completing the drive train.<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhOwvdgkrHLWZW4gMeNHrNBpfyI9Htw-sv9kIhK_8UJKCJ6-ygKFDQXyHd8uer8G-6_iSpk20g6XMX2rcI65ILd4Xd3_jwCs1TLwu5Sk40dbsTO0ShALqKkC_u0L6kM9_ZecOOG73VkCGls/s1600-h/IM000478.JPG"><img id="BLOGGER_PHOTO_ID_5295836031349593298" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhOwvdgkrHLWZW4gMeNHrNBpfyI9Htw-sv9kIhK_8UJKCJ6-ygKFDQXyHd8uer8G-6_iSpk20g6XMX2rcI65ILd4Xd3_jwCs1TLwu5Sk40dbsTO0ShALqKkC_u0L6kM9_ZecOOG73VkCGls/s320/IM000478.JPG" border="0" /></a><br />Series wound electric motors, like the kind I plan to use in my conversion, are susceptible to over-spinning and destroying themselves if power is applied while not under load (i.e. if the accelerator is pressed while the car is in neutral). To protect the motor, I would like to have a lock-out so the motor cannot be energized when the transmission is in neutral. Here I have drilled a hole in the transmission casing to receive a spare reverse indicator switch, which I will use as a neutral indicator switch.<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnpDeiU7moeBwliVKVFWVYRXJbEeTP2ay251ClnDQK-eakXtU2c5zlIEzAbmXTeQdXyTAopwxVLJ9QCAugMaCgo78t5TQP0Zb9psSrUpy6PKr1w06QNk0yU0unihYRLSwlfbLv_OMtNSuM/s1600-h/IM000482.JPG"><img id="BLOGGER_PHOTO_ID_5295837959497576114" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnpDeiU7moeBwliVKVFWVYRXJbEeTP2ay251ClnDQK-eakXtU2c5zlIEzAbmXTeQdXyTAopwxVLJ9QCAugMaCgo78t5TQP0Zb9psSrUpy6PKr1w06QNk0yU0unihYRLSwlfbLv_OMtNSuM/s320/IM000482.JPG" border="0" /></a><br />On the gear selector shaft, I have added a set of copper sleeves to push against the switch when in the mid position. Pieces of regular copper plumbing did just the job.<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUrBTLLweQU-zDEQJ_N0gFQqKRx6t4NBYM9ibizOkVLo18QlvQVJqR6q612WzHBn43NlaRDZjj1o9sfB_QpgKhIwCXR3Vyz7aybBO418eibzC6yMdjcCgCnuM-EWsLowKCKP20TET99M14/s1600-h/IM000484.JPG"><img id="BLOGGER_PHOTO_ID_5295839430845331698" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUrBTLLweQU-zDEQJ_N0gFQqKRx6t4NBYM9ibizOkVLo18QlvQVJqR6q612WzHBn43NlaRDZjj1o9sfB_QpgKhIwCXR3Vyz7aybBO418eibzC6yMdjcCgCnuM-EWsLowKCKP20TET99M14/s320/IM000484.JPG" border="0" /></a><br />The final assembly, and it works.<br /><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEipr6g4raJ2J_KYHEzngCSv2LylCiEPJcSI2b8e30t1c-X-oBxrcWQohqa3YEB_8jz5X6JFoK-Et2Q5bS10sQJ6-n8z6DM8dXLIr8NFe3PUxcza0ShDBFx_XCqgrqtV71H-ZyMbfaaH8PyT/s1600-h/IM000450.JPG"><img id="BLOGGER_PHOTO_ID_5292443591222614658" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEipr6g4raJ2J_KYHEzngCSv2LylCiEPJcSI2b8e30t1c-X-oBxrcWQohqa3YEB_8jz5X6JFoK-Et2Q5bS10sQJ6-n8z6DM8dXLIr8NFe3PUxcza0ShDBFx_XCqgrqtV71H-ZyMbfaaH8PyT/s320/IM000450.JPG" border="0" /></a><br />In researching methods of DIY car painting, I found many reports of people having good success using a roller to apply the paint. Using a front fender as a test piece, I am applying a first coat of paint using a high density 4" roller. The paint is thinned about 15%. It looks like there are lots of bubbles here, but most disappear before the paint dries.<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjz-akHyIhoIrI3rjvtuBszXaJfQHJ0SgXcAO1GJ6xv-FoNUgNYHpv2UrL6oau49ipz1XZf2PUMM4V4FaahjkhIOXpjb1E8XyI7imIMEYPs28ughOGyk2lCbn7vWQzUj42Jzo3S-1FehXNY/s1600-h/IM000483.JPG"><img id="BLOGGER_PHOTO_ID_5295834228431147794" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjz-akHyIhoIrI3rjvtuBszXaJfQHJ0SgXcAO1GJ6xv-FoNUgNYHpv2UrL6oau49ipz1XZf2PUMM4V4FaahjkhIOXpjb1E8XyI7imIMEYPs28ughOGyk2lCbn7vWQzUj42Jzo3S-1FehXNY/s320/IM000483.JPG" border="0" /></a><br /><br />The trick to this method is a color sand between coats to remove imperfections, and the occasional bubble that didn't pop. This is the fender after after about 4 coats and some wet color sanding. <br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWPuiEeDsdLeb7RwQ3hEbUEWLxq2cFD7rngMIk14GvyDvK8jE9yVEt5Qr9V4YYnSpyt6nOOP-eLLsLdiSQ0rVPUqnDgmY5WYC_J1I5shS35V4jufkfb46P_G3WEbAmgtJue0L-ppXVKlaf/s1600-h/IM000493.JPG"><img style="float:left; margin:0 10px 10px 0;cursor:pointer; cursor:hand;width: 320px; height: 240px;" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiWPuiEeDsdLeb7RwQ3hEbUEWLxq2cFD7rngMIk14GvyDvK8jE9yVEt5Qr9V4YYnSpyt6nOOP-eLLsLdiSQ0rVPUqnDgmY5WYC_J1I5shS35V4jufkfb46P_G3WEbAmgtJue0L-ppXVKlaf/s320/IM000493.JPG" border="0" alt=""id="BLOGGER_PHOTO_ID_5300534087231580370" /></a>After another two coats, more sanding, finishing with 1500 grit paper, a buffing with rubbing compound, then polishing compound, it looks not bad.DrDonhttp://www.blogger.com/profile/00507851363454428274noreply@blogger.com0tag:blogger.com,1999:blog-2456430570966606735.post-45585688669610848532009-01-05T20:59:00.000-08:002009-01-17T17:35:24.908-08:00shifter and other body workIt's been -30C outside (and in my garage) these last few weeks, so I'm mostly working on things I can do inside the house.<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjlz1JGwe4RBITj38JfcQb6Y22Q2-kPODkaB4hF8QH6FgpYAcjANnWo-Y3ovJxZnbOUoBPfgBpok2S7yQ8lg7nPYh2QWDA7U4Is3A_Uc8q_zzNCL3gEWTYTod099VbZppbQEn0sW9gum66n/s1600-h/IM000430.JPG"><img id="BLOGGER_PHOTO_ID_5288046686765992802" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjlz1JGwe4RBITj38JfcQb6Y22Q2-kPODkaB4hF8QH6FgpYAcjANnWo-Y3ovJxZnbOUoBPfgBpok2S7yQ8lg7nPYh2QWDA7U4Is3A_Uc8q_zzNCL3gEWTYTod099VbZppbQEn0sW9gum66n/s320/IM000430.JPG" border="0" /></a><br />Finding a shift lever for a Chevette 4-speed (i.e. the transmission I am using) is a real challenge. The recent hike in the price of steel has sent a lot of these cars to the crusher. "You should have come 6 months ago" I was often told while searching for this part. My transmission supplier was able to find something close (the parts on the right), which I have to fit into the control housing on the left.<br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgx2sUdZuv4dz-hNhKsogZwum-_5Cc9nIpD4xVoBrx5TozG2_JBGOYnuqDnM9GQMcUMj0MBEww_LT0_C-8IIx_DNvUSFUPsmkV3FvIN6ZJEctLFErHjdLzk5dffg2fpfQqURH02kpqrZTP-/s1600-h/IM000437.JPG"><img id="BLOGGER_PHOTO_ID_5288046509692115170" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgx2sUdZuv4dz-hNhKsogZwum-_5Cc9nIpD4xVoBrx5TozG2_JBGOYnuqDnM9GQMcUMj0MBEww_LT0_C-8IIx_DNvUSFUPsmkV3FvIN6ZJEctLFErHjdLzk5dffg2fpfQqURH02kpqrZTP-/s320/IM000437.JPG" border="0" /></a><br />With a little bit of cutting and turning, a workable solution was obtained.<br /><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhihjveXwuFI-LR4fCXuQIuXJm0JupMA2_3lEGFOBLriKd-vKasCau23TRuIWBKuIz8y86S9UaVbLWVX3TycWAbpvWANnpo9slO52PYAlvOF9beR1m4kdEdxZsrn9QrMqAa3T2i2gTScxNt/s1600-h/IM000370.JPG"><img id="BLOGGER_PHOTO_ID_5288046135838749186" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhihjveXwuFI-LR4fCXuQIuXJm0JupMA2_3lEGFOBLriKd-vKasCau23TRuIWBKuIz8y86S9UaVbLWVX3TycWAbpvWANnpo9slO52PYAlvOF9beR1m4kdEdxZsrn9QrMqAa3T2i2gTScxNt/s320/IM000370.JPG" border="0" /></a><br />The inside of the steering gear box. As per my Yahoo Group contacts, the lubrication to use here is gear oil.<br /><br /><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWqQ1sDywfUctLiK6fGeQQlzE0jM3PeYC3nehZq8NZoD119RXjwP8RlWRPkdmRID9n-VoGmlSFTX-5GD45GDB1-ytm0jIhb5U6FvvFEdZ_UTP3PO3J5vHDMzoV9L00vhj69Vd012IO5etn/s1600-h/IM000416.JPG"><img id="BLOGGER_PHOTO_ID_5288045913230984946" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWqQ1sDywfUctLiK6fGeQQlzE0jM3PeYC3nehZq8NZoD119RXjwP8RlWRPkdmRID9n-VoGmlSFTX-5GD45GDB1-ytm0jIhb5U6FvvFEdZ_UTP3PO3J5vHDMzoV9L00vhj69Vd012IO5etn/s320/IM000416.JPG" border="0" /></a><br />The existing seal for the pitman arm shaft would certainly not hold oil, so I renewed it.<br /><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgDeov2kVMlfNJVloHW63ui3HmlsNP451XwY1qxIlRMDiSy1WNwOFtB3BnIJ49nrjTg7DngdLuwa07acH8lb1DD7NHFvzxi-iPcQqN1HoBgjV55THI56jXGJf5lWxJ2s-Dtdz7Rx1GUFeHT/s1600-h/IM000375.JPG"><img id="BLOGGER_PHOTO_ID_5288045672279113266" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgDeov2kVMlfNJVloHW63ui3HmlsNP451XwY1qxIlRMDiSy1WNwOFtB3BnIJ49nrjTg7DngdLuwa07acH8lb1DD7NHFvzxi-iPcQqN1HoBgjV55THI56jXGJf5lWxJ2s-Dtdz7Rx1GUFeHT/s320/IM000375.JPG" border="0" /></a><br />In this North American version of a British car, the steering and foot pedals are all on the left hand side, however, for some reason the manufacturer didn't switch over the door lock to the driver door. Thus, locking and unlocking the car by key has be done on the passenger side (there's only one lock). Seeing this would not be convenient, I decided to move the lock over. By rubbing a card over the holes for the key and handle assembly, I am making a template to mark the hole locations for the other door.<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5YXkeeS8uLwSfBeyXoxxEMo7Mz_4Owk0vIGttYEm-MmkZnqpA1_-Zei7hbkKzTidVzqqxrZX8ngd1BoujSgwkXyJp_T4m_SGy9dYycdnPnMW8ZW2lbnTUduXqQ9KDVGkouS1jzy7EmHKN/s1600-h/IM000441.JPG"><img id="BLOGGER_PHOTO_ID_5292425135201756258" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj5YXkeeS8uLwSfBeyXoxxEMo7Mz_4Owk0vIGttYEm-MmkZnqpA1_-Zei7hbkKzTidVzqqxrZX8ngd1BoujSgwkXyJp_T4m_SGy9dYycdnPnMW8ZW2lbnTUduXqQ9KDVGkouS1jzy7EmHKN/s320/IM000441.JPG" border="0" /></a><br />Using the template, I have cut the hole for the key lock.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgtTtbfaVJ0P7bJEOuN_7PE5V1e5LpUSONvCiiuDs6PF0p5CWEqqcK0_71U1dG25jGuKZ7IuTPXv-fYoUVtC7ZZlF-iQjRvP52vDYkJeETUsXPyeq0-9-xVxd6Te90zfrmUPx6qcVmGrilA/s1600-h/IM000445.JPG"><img id="BLOGGER_PHOTO_ID_5292426062124263394" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgtTtbfaVJ0P7bJEOuN_7PE5V1e5LpUSONvCiiuDs6PF0p5CWEqqcK0_71U1dG25jGuKZ7IuTPXv-fYoUVtC7ZZlF-iQjRvP52vDYkJeETUsXPyeq0-9-xVxd6Te90zfrmUPx6qcVmGrilA/s320/IM000445.JPG" border="0" /></a><br />A pic of the lock mechanism inside the door. The only modification required was to add a copper bushing to the handle to better guide the shoot bolt.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLJXmQRAcfP6JyFAni80zxWlSWZO2sk8H5y3-qKetQmz1mYcbbEn86az-1CZtc7_L7xZzYFM1akzv9W9LOjywqhJndCHiwRcCNB0US8sJxKvEkTEufYAzM_CGRapHIOALgPYP6osB-2yHH/s1600-h/IM000446.JPG"><img id="BLOGGER_PHOTO_ID_5292429077580513890" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLJXmQRAcfP6JyFAni80zxWlSWZO2sk8H5y3-qKetQmz1mYcbbEn86az-1CZtc7_L7xZzYFM1akzv9W9LOjywqhJndCHiwRcCNB0US8sJxKvEkTEufYAzM_CGRapHIOALgPYP6osB-2yHH/s320/IM000446.JPG" border="0" /></a><br />I now have my door lock on the driver door.<br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgDPJTKCpl861tdgeVkrMJN28gAfzOaq5edXoP20EFK6Mdqjk5dRYKaFH9qqxqmLUhzjxxGqCaZBHxmqA4Zyk1Nu0SI5QXqw-R0ISRaaIuKi2cp3PYbXRtZCwV9jxsHyNK0pzJcIlqRGYt8/s1600-h/IM000397.JPG"><img id="BLOGGER_PHOTO_ID_5288045378187423778" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgDPJTKCpl861tdgeVkrMJN28gAfzOaq5edXoP20EFK6Mdqjk5dRYKaFH9qqxqmLUhzjxxGqCaZBHxmqA4Zyk1Nu0SI5QXqw-R0ISRaaIuKi2cp3PYbXRtZCwV9jxsHyNK0pzJcIlqRGYt8/s320/IM000397.JPG" border="0" /></a><br />While most of the car is relatively undamaged, the front fascia was a rather twisted piece of metal .<br /><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgxujCySlpuvsYlEbgVmUXqNoagVu8fIGh6K8Q3DVK2wMAslBCbf4Qt5UWUNSguuv8ZgWM8bv1a2_0OwLUNKQQTe4KzO84JIK3B1y-uAd5IGkB2x-p0yGiCJ1DIZUVbyLyoOtxPAp6Ey1Ah/s1600-h/IM000440.JPG"><img id="BLOGGER_PHOTO_ID_5288045155801524946" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgxujCySlpuvsYlEbgVmUXqNoagVu8fIGh6K8Q3DVK2wMAslBCbf4Qt5UWUNSguuv8ZgWM8bv1a2_0OwLUNKQQTe4KzO84JIK3B1y-uAd5IGkB2x-p0yGiCJ1DIZUVbyLyoOtxPAp6Ey1Ah/s320/IM000440.JPG" border="0" /></a><br />After some hammering, it got reasonably straight. The rest will have to rely on putty filler.<br /><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgz8wG_CTHVbsfSqmjQ42wLB8G44wbBS7HHl88LGFOTtkea3SGLOTodnjRGjEXaW66sN74H0MIK6PyDv1RGRfo9v9DNTPqR6aMfnezzD19OYnv_rKVqrMtbFKQZI8Ol_kEwtdrbLtlRYkcr/s1600-h/IM000400.JPG"><img id="BLOGGER_PHOTO_ID_5288042080245426962" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgz8wG_CTHVbsfSqmjQ42wLB8G44wbBS7HHl88LGFOTtkea3SGLOTodnjRGjEXaW66sN74H0MIK6PyDv1RGRfo9v9DNTPqR6aMfnezzD19OYnv_rKVqrMtbFKQZI8Ol_kEwtdrbLtlRYkcr/s320/IM000400.JPG" border="0" /></a><br />Making new interior door panels. The old ones were water damaged, and as I found out too late, had shrunk rather significantly such that they weren't reliable to use as templates for the new ones.<br /><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjaHURG_tRCVyx4xgFNyAS6QCmHQEpM4KYUc1sQIf1nEcL7fZCMXo8vwfGzHI0yjmFuQBIg8DaXvY5_x14-dD5KLuWnOcKf-XvhytLf4tqtuAl3fEHrchdEfB4N1LafJtQThfK8qFGxS-vS/s1600-h/IM000434.JPG"><img id="BLOGGER_PHOTO_ID_5288041905768732962" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjaHURG_tRCVyx4xgFNyAS6QCmHQEpM4KYUc1sQIf1nEcL7fZCMXo8vwfGzHI0yjmFuQBIg8DaXvY5_x14-dD5KLuWnOcKf-XvhytLf4tqtuAl3fEHrchdEfB4N1LafJtQThfK8qFGxS-vS/s320/IM000434.JPG" border="0" /></a><br />I thought I would use a stiffer material (5 ply veneer) rather than Masonite, however I didn't notice the panels need to have a slight bend at the top end, to which my panels resisted. Using a router, I cut grooves where the bend needs to be (see previous photo), and used a clamping jig to form a permanent bend.<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzYKFRsLTIDmVqo6cUNZeoksY5dj0j6qj9wv7TibW46O1boPoS9jfQESVqi_QRY4SKOcLa52gbc_D1DBRwSM9z6YyjTf6Tedzkl7dQs7ptPKugaeSDLg8IyQEuDcLJGXb2muBgGC8qmcYs/s1600-h/IM000458.JPG"><img id="BLOGGER_PHOTO_ID_5292436098270825010" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjzYKFRsLTIDmVqo6cUNZeoksY5dj0j6qj9wv7TibW46O1boPoS9jfQESVqi_QRY4SKOcLa52gbc_D1DBRwSM9z6YyjTf6Tedzkl7dQs7ptPKugaeSDLg8IyQEuDcLJGXb2muBgGC8qmcYs/s320/IM000458.JPG" border="0" /></a><br />The panels are painted, and then covered with a padded vinyl. </div></div></div></div></div></div></div></div>DrDonhttp://www.blogger.com/profile/00507851363454428274noreply@blogger.com0tag:blogger.com,1999:blog-2456430570966606735.post-82989681750023621822009-01-03T10:21:00.000-08:002009-01-07T21:44:29.748-08:00Adapter plate machining and transmission assembly<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUbJad-0l4zVk84uNwtNr8_Gje-YIf8UgTI3vm1dqnU9VRMGV87Ele1_2wZY9xm9HA-FxDrrWu63St_EthGLlje2uMo2YwJQzb-bMWKX8sJW8mG4BzaUYlTuSKYaZD9Tu4dWbZ9iqRVfWa/s1600-h/IM000403.JPG"><img id="BLOGGER_PHOTO_ID_5287141191803201346" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUbJad-0l4zVk84uNwtNr8_Gje-YIf8UgTI3vm1dqnU9VRMGV87Ele1_2wZY9xm9HA-FxDrrWu63St_EthGLlje2uMo2YwJQzb-bMWKX8sJW8mG4BzaUYlTuSKYaZD9Tu4dWbZ9iqRVfWa/s320/IM000403.JPG" border="0" /></a><br /><br />The adapter plate is made from a 1/2 inch thick 6061 aluminum plate, which as mentioned previously, I purchased as an <span class="blsp-spelling-error" id="SPELLING_ERROR_0">offcut</span> where the dimensions reach exactly to the edges of the bell housing. I may only need only to trim some of the corners off, which is a significant relief as cutting 1/2 plate with home tools is a slow process.<br /><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYTpFhA_Be3qCI_a2KapYVPjH-uGFagRIJb2cVUtOnMGgrPHRt0M7TSs-awt790UPhGmL9WoSUWrzDFwwo4vwZkR1Ug24K-DpVB8wc8AZllTcdIOy6xlJEd2G8OdyCEk5vvSE-JXQJezs6/s1600-h/IM000404.JPG"><img id="BLOGGER_PHOTO_ID_5287140930550562450" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjYTpFhA_Be3qCI_a2KapYVPjH-uGFagRIJb2cVUtOnMGgrPHRt0M7TSs-awt790UPhGmL9WoSUWrzDFwwo4vwZkR1Ug24K-DpVB8wc8AZllTcdIOy6xlJEd2G8OdyCEk5vvSE-JXQJezs6/s320/IM000404.JPG" border="0" /></a><br />It is critical that the electric motor be concentric with the transmission shaft, therefore I thought it best to keep the plate and the transmission indexed with a pair of guide pins. This will also allow for some forgiveness on any misalignment or play in the other bolt holes to be drilled, while not affecting the overal plate alignment.<br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikun-Td-Q__pjgTkJlfQL8l_6Ykfv0axxXoc6PxrHx1x5RfPIMbQ2S338U3ScAWJgqoSP7BrFxxGhLgQ9qUcF2lsssqLeZMeay3sms-3p9WRjOA0jutqHFqlW9Trl-Co8aY-kdC4IJZGTj/s1600-h/IM000405.JPG"><img id="BLOGGER_PHOTO_ID_5287140748520508114" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEikun-Td-Q__pjgTkJlfQL8l_6Ykfv0axxXoc6PxrHx1x5RfPIMbQ2S338U3ScAWJgqoSP7BrFxxGhLgQ9qUcF2lsssqLeZMeay3sms-3p9WRjOA0jutqHFqlW9Trl-Co8aY-kdC4IJZGTj/s320/IM000405.JPG" border="0" /></a><br />Using a punch and a centering tool (i.e. various bits of tubing) to mark the center for the holes.<br /><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1c95dcWL5gSRmUZgndnquN3WtGBrXS1bPO0FzVXyg9X833_HSd2nW1zM6sXkPJlYexWxDZglldmWYihKcS6BuVNBtFVJq3y00GesRT4aKZcG-L18C5OepHXWvt-ExUOuzAK3xqYKzoriF/s1600-h/IM000406.JPG"><img id="BLOGGER_PHOTO_ID_5287140589345399890" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg1c95dcWL5gSRmUZgndnquN3WtGBrXS1bPO0FzVXyg9X833_HSd2nW1zM6sXkPJlYexWxDZglldmWYihKcS6BuVNBtFVJq3y00GesRT4aKZcG-L18C5OepHXWvt-ExUOuzAK3xqYKzoriF/s320/IM000406.JPG" border="0" /></a><br />Drilling the holes. You can see why some forgiveness in hole alignment is needed, as the drill does tend to wander with this kind of set-up.<br /><br /><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgd3kkVNQI2w4MPIq8hV8JFPOMiOyOWX-WdGorJSdWX9M-jDKbGGKM6ltxI8gM99nsbBtFwOxg7LlJRBmkQSUM8WWqEzG9Ce664XOT4wU8UM3QbZvE5jDjQ2uvYHQTDGoHemwJEwOHU3IGl/s1600-h/IM000407.JPG"><img id="BLOGGER_PHOTO_ID_5287140411841244098" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgd3kkVNQI2w4MPIq8hV8JFPOMiOyOWX-WdGorJSdWX9M-jDKbGGKM6ltxI8gM99nsbBtFwOxg7LlJRBmkQSUM8WWqEzG9Ce664XOT4wU8UM3QbZvE5jDjQ2uvYHQTDGoHemwJEwOHU3IGl/s320/IM000407.JPG" border="0" /></a><br />Taping the holes that will receive bolts.<br /><br /><br /><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyLd0eZJ6GArGl4CJh-Od5RDliIwQ68I_HvprVaa_v57o9xcEv9eYf3utOAHAhGqf1rbciFU1gKy1_A62-_lBivhE5tzqK8WV9yFFL3cvckIX9eAIS0yDZWi5wbSn15tnHwvU2ywKr7kpC/s1600-h/IM000408.JPG"><img id="BLOGGER_PHOTO_ID_5287140270211866690" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgyLd0eZJ6GArGl4CJh-Od5RDliIwQ68I_HvprVaa_v57o9xcEv9eYf3utOAHAhGqf1rbciFU1gKy1_A62-_lBivhE5tzqK8WV9yFFL3cvckIX9eAIS0yDZWi5wbSn15tnHwvU2ywKr7kpC/s320/IM000408.JPG" border="0" /></a><br />Checking the hole alignment. Only a couple holes needed touching up with a rat-tail file.<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWEqYN7fwcSqkZeE27LH9K93VMlNK3SAcao6O0Ju3kxXC5hXpvzrGnXffJkOw12gjgp-kyyNSJAnvK9c3zsyP4KD2ESvWyBw3izvzqm583D_Pvrf9XHitRGEZDOTKSvN8Cx_Ue5Bmqi9tb/s1600-h/IM000413.JPG"><img id="BLOGGER_PHOTO_ID_5287148535969436322" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjWEqYN7fwcSqkZeE27LH9K93VMlNK3SAcao6O0Ju3kxXC5hXpvzrGnXffJkOw12gjgp-kyyNSJAnvK9c3zsyP4KD2ESvWyBw3izvzqm583D_Pvrf9XHitRGEZDOTKSvN8Cx_Ue5Bmqi9tb/s320/IM000413.JPG" border="0" /></a><br />Cutting the hole for the motor shaft with a jig saw. Very slow going. Applying oil to the blade seemed to help.<br /><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3gUrm8DX3WwMGJWkPLNu7hqI8MWHB68jY-oC01vAuL6K-oTcTT59J8O8PzbypxQQQgtKKjxiiYGlbJ3ZvCCP06c6X9-RCPSTL8unwLt8xtCoUe2dPFXUBk_w4OXufbGdKTMJiwH9za4ue/s1600-h/IM000413+(2).JPG"><img id="BLOGGER_PHOTO_ID_5287140024923799442" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEg3gUrm8DX3WwMGJWkPLNu7hqI8MWHB68jY-oC01vAuL6K-oTcTT59J8O8PzbypxQQQgtKKjxiiYGlbJ3ZvCCP06c6X9-RCPSTL8unwLt8xtCoUe2dPFXUBk_w4OXufbGdKTMJiwH9za4ue/s320/IM000413+(2).JPG" border="0" /></a><br />Finally done. The hole is actually slightly undersized, as the plan is to make the hole concentric when it is enlarged, as I will only know where the exact centre is once <span class="blsp-spelling-corrected" id="SPELLING_ERROR_1">everything</span> is assembled.<br /><br /><br /><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhR7BRMVM-4zbkF-QtxeTmltGUNfoehNkJWbDr3XdM5ABjyX-7rJhbrVeTWEGWb95Ywb2mrD-OBg4uHkDL3IQ-dGmJKuJKLhOU-7QbT5n81hODGtYt7lPF15Vgwj17BBWI6G4Muyn18mCkR/s1600-h/IM000423.JPG"><img id="BLOGGER_PHOTO_ID_5287139675449723938" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhR7BRMVM-4zbkF-QtxeTmltGUNfoehNkJWbDr3XdM5ABjyX-7rJhbrVeTWEGWb95Ywb2mrD-OBg4uHkDL3IQ-dGmJKuJKLhOU-7QbT5n81hODGtYt7lPF15Vgwj17BBWI6G4Muyn18mCkR/s320/IM000423.JPG" border="0" /></a><br />Now to put the transmission transmission together, which <span class="blsp-spelling-corrected" id="SPELLING_ERROR_2">hopefully</span> will be easier than the <span class="blsp-spelling-corrected" id="SPELLING_ERROR_3">disassembly</span>. Because of the erroneous directions from the Chilton manual, many loose part fell out the casing before I could see where they came from, which included 16 roller bearings for the main shaft. However, in putting things toghether, there is only room for 15 pins. I'm hoping that the extra pin was just a loose one left behind in the transmission by GM.<br /><br /><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8evMOuuehklQpeVjnE3o3ZhMTjrf9j2ydQPPczb6cBn9ZbA9p1ECV4_0R2-AU1tv3tqllRJy4ij68v4_yW4bbLyJEnpcnN8yiLv_lATYoskZBYI6U525P7hqANAauT6geFF7CEq-5O-7T/s1600-h/IM000424.JPG"><img id="BLOGGER_PHOTO_ID_5287139526083875090" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh8evMOuuehklQpeVjnE3o3ZhMTjrf9j2ydQPPczb6cBn9ZbA9p1ECV4_0R2-AU1tv3tqllRJy4ij68v4_yW4bbLyJEnpcnN8yiLv_lATYoskZBYI6U525P7hqANAauT6geFF7CEq-5O-7T/s320/IM000424.JPG" border="0" /></a><br />The main shaft, counter shaft, and gear selector mechanism before <span class="blsp-spelling-corrected" id="SPELLING_ERROR_4">slipping</span> over the casing.<br /><br /><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIsVkhZ1o05JaMBm4wF2e_4niVSWhw7ONczaohIGC5JzfpwfT0A90kMznbnkfkwV_lKqH6-OKkfRwh7Wl4A8AbjWRy4eLRGJ5YSDlnJUNjVZc-xykOgqGbb4yaQBKSxCz93dPefE9sD0I3/s1600-h/IM000426.JPG"><img id="BLOGGER_PHOTO_ID_5287139367458331138" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgIsVkhZ1o05JaMBm4wF2e_4niVSWhw7ONczaohIGC5JzfpwfT0A90kMznbnkfkwV_lKqH6-OKkfRwh7Wl4A8AbjWRy4eLRGJ5YSDlnJUNjVZc-xykOgqGbb4yaQBKSxCz93dPefE9sD0I3/s320/IM000426.JPG" border="0" /></a><br />The cover installed<br /><br /><br /><br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgxTDOOVSpSVOyf7bbQMh3N5xmLSmfZj3wbBdX_9ppsNlwXx8CUk56dLTi5N3n3iCV-dYbLbaj81_vRdJjmV62KRvd-Ue0_ia5Q0LeViDvMjFwxULW_kDIny66u1ArdnSUpIIJGS8Nd2rvN/s1600-h/IM000427.JPG"><img id="BLOGGER_PHOTO_ID_5287139201840575714" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgxTDOOVSpSVOyf7bbQMh3N5xmLSmfZj3wbBdX_9ppsNlwXx8CUk56dLTi5N3n3iCV-dYbLbaj81_vRdJjmV62KRvd-Ue0_ia5Q0LeViDvMjFwxULW_kDIny66u1ArdnSUpIIJGS8Nd2rvN/s320/IM000427.JPG" border="0" /></a><br />Here are the aluminium <span class="blsp-spelling-corrected" id="SPELLING_ERROR_5">couplers</span> with an <span class="blsp-spelling-error" id="SPELLING_ERROR_6">elastomer</span> spider that I will use. These are very light, and should not add too much to the rotational inertia that the <span class="blsp-spelling-error" id="SPELLING_ERROR_7">synchronizers</span> will have deal with when shifting, as this is a <span class="blsp-spelling-error" id="SPELLING_ERROR_8">clutchless</span> system. Now I wait for my motor to come before making final adjustments to the plate.</div></div></div></div></div></div></div></div></div></div>DrDonhttp://www.blogger.com/profile/00507851363454428274noreply@blogger.com0tag:blogger.com,1999:blog-2456430570966606735.post-6217853261216695192008-12-28T07:29:00.000-08:002008-12-29T13:18:44.534-08:00Machining the transmission input shaft and other work....<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyoAWS_onj2gjR3MCd5LQPAFcq9HSsp1SLsbUx-jQibBwZGioismRbMuMKfr7E73dlDJiTc9uGEwHt50YLqS72qoaYyMSWOKpD2LdFa2vcQawqM4PVva2SXeifMb972WeI_81MLrSUJwvu/s1600-h/IM000377.JPG"><img id="BLOGGER_PHOTO_ID_5284870053503379298" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyoAWS_onj2gjR3MCd5LQPAFcq9HSsp1SLsbUx-jQibBwZGioismRbMuMKfr7E73dlDJiTc9uGEwHt50YLqS72qoaYyMSWOKpD2LdFa2vcQawqM4PVva2SXeifMb972WeI_81MLrSUJwvu/s320/IM000377.JPG" border="0" /></a>My plan to couple the electric motor to the <span class="blsp-spelling-corrected" id="SPELLING_ERROR_0">transmission</span> is to use a pair of <span class="blsp-spelling-error" id="SPELLING_ERROR_1"><span class="blsp-spelling-error" id="SPELLING_ERROR_0">Lovejoy</span></span> connectors. However, the transmission has a <span class="blsp-spelling-error" id="SPELLING_ERROR_2"><span class="blsp-spelling-error" id="SPELLING_ERROR_1">splined</span></span> shaft, whereas the couplers are made to fit on a keyed shaft. The simplest solution is to machine the input shaft to accept the coupler. To do this, I have set up my mini-lather to have a grinder in the place of the cutting tool, as the shaft is hardened steel and cannot be cut using a carbide bit..<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhb3_8DXpOXEUBxhEZWadUACwpTTSSwJqGzkpe9x_CBVYZB4ifW77ZGP4Yc1mhyZ4wd_vPpqCi5ckuUxvcoBCcleRstxOMuTEBgArqvEuZcsQqnO0ZnuWi6yp-mi7MJUp9muofAg6aL8FCc/s1600-h/IM000381.JPG"><img id="BLOGGER_PHOTO_ID_5284869899866669042" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhb3_8DXpOXEUBxhEZWadUACwpTTSSwJqGzkpe9x_CBVYZB4ifW77ZGP4Yc1mhyZ4wd_vPpqCi5ckuUxvcoBCcleRstxOMuTEBgArqvEuZcsQqnO0ZnuWi6yp-mi7MJUp9muofAg6aL8FCc/s320/IM000381.JPG" border="0" /></a>I ground down the shaft to the next largest shaft <span class="blsp-spelling-corrected" id="SPELLING_ERROR_3">diameter</span> (i.e. 7/8") based on the available coupler sizes.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiijz5pLesfJyHZidmp3x6Z7sAvQFbMfxMiEfh8QMDjYv8NsITAVQPRV6oZKXfTSNCv6oXJ-MnB0s2UUrAwGAoWun7DrM8xclZzb5HPLv-k2QZLjMbsCM1nE4NH3-xHwwmg_I-QRx9lnOgW/s1600-h/IM000383.JPG"><img id="BLOGGER_PHOTO_ID_5284869737202522418" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiijz5pLesfJyHZidmp3x6Z7sAvQFbMfxMiEfh8QMDjYv8NsITAVQPRV6oZKXfTSNCv6oXJ-MnB0s2UUrAwGAoWun7DrM8xclZzb5HPLv-k2QZLjMbsCM1nE4NH3-xHwwmg_I-QRx9lnOgW/s320/IM000383.JPG" border="0" /></a>The machining only required removing about 0.5 mm (0.02 in.) from the main shaft, but most of the spline teeth are now gone with just the roots remaining. (The area machined appears darker here and starts midway down the shaft)<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8LmOKibj5gdDVbieLBmkFg-4QWoCV2xAwFEsHWt48UGZg7WqGHGBoa4RFlD8i1owRYOb9QqA_N919zoxWi0k8xWndKbQ-2HPud5N81NO8qfgm_tchN5NTotbAQP-rpPIjoOM_wQG0IxVp/s1600-h/IM000386.JPG"><img id="BLOGGER_PHOTO_ID_5284869592826837330" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEj8LmOKibj5gdDVbieLBmkFg-4QWoCV2xAwFEsHWt48UGZg7WqGHGBoa4RFlD8i1owRYOb9QqA_N919zoxWi0k8xWndKbQ-2HPud5N81NO8qfgm_tchN5NTotbAQP-rpPIjoOM_wQG0IxVp/s320/IM000386.JPG" border="0" /></a>Using the grinder again, this time to cut a <span class="blsp-spelling-error" id="SPELLING_ERROR_4"><span class="blsp-spelling-error" id="SPELLING_ERROR_2">keyway</span></span> down the length of the shaft. Here, I slide the shaft along the grinding wheel until the desired depth is reached, repeating the process after shimming up the sliding surface to get the right width of cut.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEid1DiWiUyybcjN_-w1PYrwz1gzcuSQo_52N5XMFjCNroj3EdM4RjXdAMshMakK4HLd7kSXN0s6dB7tr6pypiwnpmIAgKzKjbyWkqsgfi0FnpWC7Hf2KlunbqrV5WEBp2pc-PNZcPCWayD_/s1600-h/IM000387.JPG"><img id="BLOGGER_PHOTO_ID_5284869437969286098" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEid1DiWiUyybcjN_-w1PYrwz1gzcuSQo_52N5XMFjCNroj3EdM4RjXdAMshMakK4HLd7kSXN0s6dB7tr6pypiwnpmIAgKzKjbyWkqsgfi0FnpWC7Hf2KlunbqrV5WEBp2pc-PNZcPCWayD_/s320/IM000387.JPG" border="0" /></a>Test fitting the coupler with a <span class="blsp-spelling-error" id="SPELLING_ERROR_5">length</span> of key stock - success. Eventually, the shaft will shortened once I determine the required <span class="blsp-spelling-error" id="SPELLING_ERROR_6">length</span>, but essentially the length protruding from the coupler in this picture will be cut off.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgghdg9elQhOsx3oSLY2cj24xXWptySPHCxBEYl2142lo-4bvfbAsoDvdU9EWm45F4AOA8WOi3jjg4ymCKmYK_FE3yOAMhaA3AQ7ZHzf3LC4RXwaC4VJmO0senB4JoF49z0RcM4GgnkKPbx/s1600-h/IM000363.JPG"><img id="BLOGGER_PHOTO_ID_5284868670357543090" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgghdg9elQhOsx3oSLY2cj24xXWptySPHCxBEYl2142lo-4bvfbAsoDvdU9EWm45F4AOA8WOi3jjg4ymCKmYK_FE3yOAMhaA3AQ7ZHzf3LC4RXwaC4VJmO0senB4JoF49z0RcM4GgnkKPbx/s320/IM000363.JPG" border="0" /></a>Meanwhile, it was time to bolt the body back to the frame, so lifting it up one last time...<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNvuR8IHn1UJVCRG30ABO6HpbHyLGu0yTPI-Y7qqyy4ImZFsfXeVWi9fwbZA4ccf1UpNgDNs-Civnh-dfNO8F-y8kXx8jp-OGuLWY-eDcSDq0KQdzbsCPXqGEayhOuclkwx05Dhj154Svv/s1600-h/IM000364.JPG"><img id="BLOGGER_PHOTO_ID_5284869135411421954" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNvuR8IHn1UJVCRG30ABO6HpbHyLGu0yTPI-Y7qqyy4ImZFsfXeVWi9fwbZA4ccf1UpNgDNs-Civnh-dfNO8F-y8kXx8jp-OGuLWY-eDcSDq0KQdzbsCPXqGEayhOuclkwx05Dhj154Svv/s320/IM000364.JPG" border="0" /></a>... and slowly <span class="blsp-spelling-corrected" id="SPELLING_ERROR_7">lowering</span> it, using screwdrivers to line up the bolt holes<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1f11Vhslq6EPNGza6wOPj7st-H8ItiF6r0zsRT-YQ0AU-0b0ZsJvW_t8zwK7oC2-Gq5mte06qAwvV1loWCI0vtOTvvG2m98C3mXqPh9GIRcSoKq00MlRBpTMEgUO10q2v47MbbwojvsSr/s1600-h/IM000373.JPG"><img id="BLOGGER_PHOTO_ID_5284868486412250562" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi1f11Vhslq6EPNGza6wOPj7st-H8ItiF6r0zsRT-YQ0AU-0b0ZsJvW_t8zwK7oC2-Gq5mte06qAwvV1loWCI0vtOTvvG2m98C3mXqPh9GIRcSoKq00MlRBpTMEgUO10q2v47MbbwojvsSr/s320/IM000373.JPG" border="0" /></a>The original master cylinder for the brakes was frame mounted and located under the driver seat. I decided to switch to a dual <span class="blsp-spelling-corrected" id="SPELLING_ERROR_8">reservoir</span> system, mounted on the firewall. The pedal assembly is a recycled part from a what I believe was a Honda (the car was not in a recognizable state), and the master cylinder is a new Mazda truck part.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijI9GQ-XGy2IP9Vqrsm3qgL09wODN3WA4tQlf946qXer2u4JhkapT_eX9qPoundcLnnSHMeprgO7p_gCzoi83cIA0XegWueLakKgfQrwN6KcQ_DQBHaqm6hl1MkH_QjaFumZkN95MBbIlY/s1600-h/IM000395.JPG"><img id="BLOGGER_PHOTO_ID_5284868368319355282" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEijI9GQ-XGy2IP9Vqrsm3qgL09wODN3WA4tQlf946qXer2u4JhkapT_eX9qPoundcLnnSHMeprgO7p_gCzoi83cIA0XegWueLakKgfQrwN6KcQ_DQBHaqm6hl1MkH_QjaFumZkN95MBbIlY/s320/IM000395.JPG" border="0" /></a>The heater control assembly, repainted and re-labelled using rub-on decals from <span class="blsp-spelling-error" id="SPELLING_ERROR_9"><span class="blsp-spelling-error" id="SPELLING_ERROR_3">Lettraset</span></span>.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKj6gCYS_1gw2agRKLAaNb_AT2BscCZXhnT7f_-xGuGBWC56e5TBDKazRJfTSRdEt6MkZjL262Z0AXmuThsnA8cVyU9qHTdzAeGFR0JTZ8OU6vTWpRlumDejRn6vxa5UJwZm8j4GDKp771/s1600-h/IM000371.JPG"><img id="BLOGGER_PHOTO_ID_5284866112747698482" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhKj6gCYS_1gw2agRKLAaNb_AT2BscCZXhnT7f_-xGuGBWC56e5TBDKazRJfTSRdEt6MkZjL262Z0AXmuThsnA8cVyU9qHTdzAeGFR0JTZ8OU6vTWpRlumDejRn6vxa5UJwZm8j4GDKp771/s320/IM000371.JPG" border="0" /></a>Steering tie rods, reconditioned and fitted with new rubber boots.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLAcGtzpk3DBNPixn2BPmot9husNypE97O6_0vy_BbHj2kvU3N0V1YgeDS3_Dp7RYTw-cqqPHmqAWCC6KBZaiDPsJmu3FZlRwH_PY-yvz5c4fT6apuHym1zUZ9NSxDtwfY4tW76vOd1FWL/s1600-h/IM000398.JPG"><img id="BLOGGER_PHOTO_ID_5284885830327011170" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjLAcGtzpk3DBNPixn2BPmot9husNypE97O6_0vy_BbHj2kvU3N0V1YgeDS3_Dp7RYTw-cqqPHmqAWCC6KBZaiDPsJmu3FZlRwH_PY-yvz5c4fT6apuHym1zUZ9NSxDtwfY4tW76vOd1FWL/s320/IM000398.JPG" border="0" /></a>A <span class="blsp-spelling-corrected" id="SPELLING_ERROR_10">convenient</span> feature of the tie rod ends for this car is that the bottom cap screws out, and thus are adjustable for wear.DrDonhttp://www.blogger.com/profile/00507851363454428274noreply@blogger.com0tag:blogger.com,1999:blog-2456430570966606735.post-57882237821863449222008-12-07T10:35:00.000-08:002009-01-03T16:05:07.531-08:00The continuation, which pretty much brings this blog up to date ....<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhdslIHaxn9dvAChgl0hvsrAFJv0wXNP_O53VqdkNUTbxrT_OOu9b6ym6jBhrUe3dRibBe_8dcBQ7XDBxNatmA_viMDlEG2noK7AvV4kKceApvwq0Z7qcuQiSQr2kvz9BZz0JqBYCyN36AL/s1600-h/IM000322.JPG"><img id="BLOGGER_PHOTO_ID_5277120841253917730" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhdslIHaxn9dvAChgl0hvsrAFJv0wXNP_O53VqdkNUTbxrT_OOu9b6ym6jBhrUe3dRibBe_8dcBQ7XDBxNatmA_viMDlEG2noK7AvV4kKceApvwq0Z7qcuQiSQr2kvz9BZz0JqBYCyN36AL/s320/IM000322.JPG" border="0" /></a><br />Here is the slip yolk from the Chevette transmission (on the left) and the U-joint cut of the original transmission's slip yolk. The plan to interface the new transmission is to put the old u-joint on the newer slip yolk.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjP4xg4vfmcwLUaeFxgshvKUqPDy_KKBFc6vWYEXvMLvQTdA6fhMakHZjf2PGELwMS_2MFHquS8dCmx8MTWR1kMIBlM4YBlBFaxANe7ZAQfASaib7vRQctQvezLXioyqd9blKMLLXOZp8eU/s1600-h/IM000330.JPG"><img id="BLOGGER_PHOTO_ID_5277121081649077218" style="FLOAT: right; MARGIN: 0px 0px 10px 10px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjP4xg4vfmcwLUaeFxgshvKUqPDy_KKBFc6vWYEXvMLvQTdA6fhMakHZjf2PGELwMS_2MFHquS8dCmx8MTWR1kMIBlM4YBlBFaxANe7ZAQfASaib7vRQctQvezLXioyqd9blKMLLXOZp8eU/s320/IM000330.JPG" border="0" /></a><br />Here is the newer slip yolk with the u-joint cut off and machined to index with the old u-joint so it stays centred.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfHzX_F0MmjmLI-QhU13bZU2Ok-Jx94uMGImi12BIkYsUi02VSkaJ2HTXJZ0lmEQzArmPvDU7UXq9UQdDqFInHAZmJAf6kEEAsnrwieWva_5-kSIALQG4Cjgz_e98BNdbk9wkH8W0VtAS5/s1600-h/IM000332.JPG"><img id="BLOGGER_PHOTO_ID_5277121261543991314" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgfHzX_F0MmjmLI-QhU13bZU2Ok-Jx94uMGImi12BIkYsUi02VSkaJ2HTXJZ0lmEQzArmPvDU7UXq9UQdDqFInHAZmJAf6kEEAsnrwieWva_5-kSIALQG4Cjgz_e98BNdbk9wkH8W0VtAS5/s320/IM000332.JPG" border="0" /></a><br />The modified parts fitted together, and eventually will be welded.<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDJREv95BKp90UdeVm_Vkuaqdm8cJnoCaoc4mO2a44oW4dXpFosiuK1_mpIxSCE7E7o3eml0RH5fv1uzGHdSMQkManRBFx9yalzpd4IJ63ln0cg41gE0TmSsJ0i0707G_Ldg64jc2qWvs4/s1600-h/IM000338.JPG"><img id="BLOGGER_PHOTO_ID_5277119244588923778" style="FLOAT: right; MARGIN: 0px 0px 10px 10px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiDJREv95BKp90UdeVm_Vkuaqdm8cJnoCaoc4mO2a44oW4dXpFosiuK1_mpIxSCE7E7o3eml0RH5fv1uzGHdSMQkManRBFx9yalzpd4IJ63ln0cg41gE0TmSsJ0i0707G_Ldg64jc2qWvs4/s320/IM000338.JPG" border="0" /></a><br /><br /><div></div><br />Fitting up the transmission to design new brackets . The slip yolk is held together with duct tape for now.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnoKL6ajFAejOLRqikiruUjLgBbT4mO_eijHS-2S7kgzw4cVy4E5xDveKd5LWhkaJ_7Uxiv65Tb7KL2WP9r-XFzhwMw6sBsDdtBXpMtwmBO-GPsECr4oFk61s5nibUqLy1zHN3B-G6pNRE/s1600-h/IM000356.JPG"><img id="BLOGGER_PHOTO_ID_5277127354689058402" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnoKL6ajFAejOLRqikiruUjLgBbT4mO_eijHS-2S7kgzw4cVy4E5xDveKd5LWhkaJ_7Uxiv65Tb7KL2WP9r-XFzhwMw6sBsDdtBXpMtwmBO-GPsECr4oFk61s5nibUqLy1zHN3B-G6pNRE/s320/IM000356.JPG" border="0" /></a><br />The bracket that I made for mounting the back end of the transmission.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJvhsrqfxVFpxW1cYcvl8cEXYUGfnG2WBNqXt2ouLSCVe1f8i30Q2yjQ491CHG59Pvi0gfENGBObm1_wg2swPHlOEEaVHun2OUb1O1omqGsf-n9KNk4pOjwHwvweDYMi-54xsq30h0T6Sn/s1600-h/IM000346.JPG"><img id="BLOGGER_PHOTO_ID_5277121703808712306" style="FLOAT: right; MARGIN: 0px 0px 10px 10px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjJvhsrqfxVFpxW1cYcvl8cEXYUGfnG2WBNqXt2ouLSCVe1f8i30Q2yjQ491CHG59Pvi0gfENGBObm1_wg2swPHlOEEaVHun2OUb1O1omqGsf-n9KNk4pOjwHwvweDYMi-54xsq30h0T6Sn/s320/IM000346.JPG" border="0" /></a><br /><br />The bell housing resting on an aluminum plate that will be the adapter for the electric motor. The metal shop had an offcut that was <em>exactly</em> the right size. Serendipity happens.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiyOjZDj3f1ZzNYKbNZHMv_5xZdfaZPnxetyvkwgwhmFgORWluvJ075hxul_qRgRzx3Ymj5QLvv7GwL6Pg3ddwwWnRjuNqUdCnKgeL4k28tviJB9tySprI_bJ8yomF2DyG-PTxvK93zfcO1/s1600-h/IM000348.JPG"><img id="BLOGGER_PHOTO_ID_5277121899664399442" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiyOjZDj3f1ZzNYKbNZHMv_5xZdfaZPnxetyvkwgwhmFgORWluvJ075hxul_qRgRzx3Ymj5QLvv7GwL6Pg3ddwwWnRjuNqUdCnKgeL4k28tviJB9tySprI_bJ8yomF2DyG-PTxvK93zfcO1/s320/IM000348.JPG" border="0" /></a><br />Starting on modifying the heater box. Here, the heater core will be replaced with the workings of a electric ceramic heater.DrDonhttp://www.blogger.com/profile/00507851363454428274noreply@blogger.com0tag:blogger.com,1999:blog-2456430570966606735.post-43336262249878179782008-12-06T22:21:00.000-08:002009-01-03T16:05:30.264-08:00Continuing on....<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-tVo2OlMQLL2prwFAjztWozUNb6nFhtO8tFTWnR-ppbqFxXmRB87iyogoPdP6LdNuUhRq4BKNTjYv3bRzht1k-RtU0CbGfBx9U_HAl2rOFNmAXQ5zmWK4sm8WS5lAbu1v8hzJXrS14bhV/s1600-h/IM000220.JPG"><img id="BLOGGER_PHOTO_ID_5276931774761117298" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh-tVo2OlMQLL2prwFAjztWozUNb6nFhtO8tFTWnR-ppbqFxXmRB87iyogoPdP6LdNuUhRq4BKNTjYv3bRzht1k-RtU0CbGfBx9U_HAl2rOFNmAXQ5zmWK4sm8WS5lAbu1v8hzJXrS14bhV/s320/IM000220.JPG" border="0" /></a><br />Pressing in new bearings and seals in the rear axle hubs.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUG0AM9a8NYqyEoLuW1Ge7HfpCnaGcQHn1FPb_w256HnywumdFJnDVgLgiRUe6LpDtiV2czutNoMIeYt865zjCG3LhrMr1yohKrJhlaBZHe6RoJkUC-Rou1ESqldLSH3eOzYo7vJGYucty/s1600-h/IM000221.JPG"><img id="BLOGGER_PHOTO_ID_5276931410476000754" style="FLOAT: right; MARGIN: 0px 0px 10px 10px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgUG0AM9a8NYqyEoLuW1Ge7HfpCnaGcQHn1FPb_w256HnywumdFJnDVgLgiRUe6LpDtiV2czutNoMIeYt865zjCG3LhrMr1yohKrJhlaBZHe6RoJkUC-Rou1ESqldLSH3eOzYo7vJGYucty/s320/IM000221.JPG" border="0" /></a><br />The seal surface on pinion gear hub was badly pitted. On the left is a speedy seal and the insertion tool, which worked great at putting a smooth seal race for the oil seal.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAK7CnCYEIJL58PeY3jrhkXuWrTr18VleOgie3T6Yo-h4VJHG5QuHZatiwGtFgRcGiGDbkSaU9j41aCTfUv4AtVbtWYRjFnepdgwdggzmfIw6fiBh7-2g63lBIt5MS4MNkFBboZcp8dYTe/s1600-h/IM000229.JPG"><img id="BLOGGER_PHOTO_ID_5276932179571737426" style="FLOAT: right; MARGIN: 0px 0px 10px 10px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhAK7CnCYEIJL58PeY3jrhkXuWrTr18VleOgie3T6Yo-h4VJHG5QuHZatiwGtFgRcGiGDbkSaU9j41aCTfUv4AtVbtWYRjFnepdgwdggzmfIw6fiBh7-2g63lBIt5MS4MNkFBboZcp8dYTe/s320/IM000229.JPG" border="0" /></a><br />Same story for the seals on the axle, which were also pitted. Here, I am midway in knocking-in a Speedy-seal on the axle.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjsPsWL5e-VhFmk3mKeaV-mWWz5lzVpdAuFgIJ0M-rFvSmY5F0d4hP967wuXFKLkHnm5k0pEVTGzZ4vhQLZcojvQ_tNpd1QE4Ucq3ws8j5RCsZXtFTBym20mMDoP9uEm6o7V9kF3EGo2nD8/s1600-h/IM000308.JPG"><img id="BLOGGER_PHOTO_ID_5276933582769614370" style="FLOAT: right; MARGIN: 0px 0px 10px 10px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjsPsWL5e-VhFmk3mKeaV-mWWz5lzVpdAuFgIJ0M-rFvSmY5F0d4hP967wuXFKLkHnm5k0pEVTGzZ4vhQLZcojvQ_tNpd1QE4Ucq3ws8j5RCsZXtFTBym20mMDoP9uEm6o7V9kF3EGo2nD8/s320/IM000308.JPG" border="0" /></a><br />New brake shoes (New Old Stock in this case), brake cylinder seals and cups get assembled<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrIy7ac2BxsJtFAx-XaRDdd8zdie9F_JMVMbSJ7NrngRUOHAmiZp_EiM78cci3lKKOt7GQ2h2NsqGBthsmXwaCGxjFKuo7bS0S1ZaqV0ahcsfZbL4EKJhXXbYWkXI4295sZPluJAA7B46_/s1600-h/IM000237.JPG"><img id="BLOGGER_PHOTO_ID_5276932380003507794" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjrIy7ac2BxsJtFAx-XaRDdd8zdie9F_JMVMbSJ7NrngRUOHAmiZp_EiM78cci3lKKOt7GQ2h2NsqGBthsmXwaCGxjFKuo7bS0S1ZaqV0ahcsfZbL4EKJhXXbYWkXI4295sZPluJAA7B46_/s320/IM000237.JPG" border="0" /></a><br />Emptying, cleaning and refilling the rear shock absorbers. The oil that came was rather dirty, as seen on the left.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi9UQz4cUjPHo81siJ8GLQYuRmtSWc6LeWkkBdlxifsIPvNEv1RwnnSGJbnkyUqpYGC7UDlcwHoFlIfBN3hM4k4IWT4BC71RY-b5U0Z0G81CqyEcxwYsQ0BQAxRFPc_2iD1iFGvGQ9dmJfH/s1600-h/IM000239.JPG"><img id="BLOGGER_PHOTO_ID_5276932646143421938" style="FLOAT: right; MARGIN: 0px 0px 10px 10px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi9UQz4cUjPHo81siJ8GLQYuRmtSWc6LeWkkBdlxifsIPvNEv1RwnnSGJbnkyUqpYGC7UDlcwHoFlIfBN3hM4k4IWT4BC71RY-b5U0Z0G81CqyEcxwYsQ0BQAxRFPc_2iD1iFGvGQ9dmJfH/s320/IM000239.JPG" border="0" /></a><br />Fitting the shock absorbers, and anti-sway bar, back on the frame.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizyQReqqPkqwA2DGChaH0nLsV-7XOzy1JZwddgymMFco5ikqysvU2SzXrc-x92_YUdN9WPhxxrGL3022vYGsHenEpaAXLNtKxkOzdJpiQSYnJEbZ1-Aw8O_0pk0bZqZnhYjSU0PFFVsw9i/s1600-h/IM000316.JPG"><img id="BLOGGER_PHOTO_ID_5276933879809067330" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEizyQReqqPkqwA2DGChaH0nLsV-7XOzy1JZwddgymMFco5ikqysvU2SzXrc-x92_YUdN9WPhxxrGL3022vYGsHenEpaAXLNtKxkOzdJpiQSYnJEbZ1-Aw8O_0pk0bZqZnhYjSU0PFFVsw9i/s320/IM000316.JPG" border="0" /></a><br />The rear axle assembly ready for fitting back on the car.<br /><div><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6g4_8-AG3bZy3HfMqzmfpCuXWRrefMOK5bbhyphenhyphenCoB9Dsxn8XSfG1PcWCxRuRSrMjztjrykix-AWpy1SfRGy9DHRExYOVJRd64KR8HvTbVPo-KLGITcEdqWMDwNP4el2aGAfLaeK3OENesS/s1600-h/IM000319.JPG"><img id="BLOGGER_PHOTO_ID_5276934211046162466" style="FLOAT: right; MARGIN: 0px 0px 10px 10px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEi6g4_8-AG3bZy3HfMqzmfpCuXWRrefMOK5bbhyphenhyphenCoB9Dsxn8XSfG1PcWCxRuRSrMjztjrykix-AWpy1SfRGy9DHRExYOVJRd64KR8HvTbVPo-KLGITcEdqWMDwNP4el2aGAfLaeK3OENesS/s320/IM000319.JPG" border="0" /></a><br />Connecting the shock absorbers.<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiU8zVh2eg8rM9EUqhZXjc8U-kCRqQ5QNEBCCtie9IW0c30nKlmfyqNJg-EvzeQp78x27ToiB5-u-s1sdudu03LmNYWR33KG2KLI8en8KDauYF8ibH4GLFAuxZ1JmFoEr-KT9DoUHOXPrTp/s1600-h/IM000204.JPG"><img id="BLOGGER_PHOTO_ID_5276930380949271682" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiU8zVh2eg8rM9EUqhZXjc8U-kCRqQ5QNEBCCtie9IW0c30nKlmfyqNJg-EvzeQp78x27ToiB5-u-s1sdudu03LmNYWR33KG2KLI8en8KDauYF8ibH4GLFAuxZ1JmFoEr-KT9DoUHOXPrTp/s320/IM000204.JPG" border="0" /></a><br />In the end, the original transmission (on the right) was not salvageable, everything was seized up. After much searching, I found a transmission, from an 1983 Chevette, that will probably work as a replacement, as it's physically about the same dimensions. Unfortunately, there is no shift lever for it yet.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiCvKFjh9Pn_q5Cvm_EwuoZZjmcFX90u_3L7N0DeHvz6Cr-EH9vo1rk2e6srBB7STM1PZNQljCpy6FxKbUCkejO2sG0J2URcTC8IAfsC9YeK-iKDJ7SXGT_1Kso9g7vdtRF0dpahYJZjWP/s1600-h/IM000211.JPG"><img id="BLOGGER_PHOTO_ID_5276930874532564034" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjiCvKFjh9Pn_q5Cvm_EwuoZZjmcFX90u_3L7N0DeHvz6Cr-EH9vo1rk2e6srBB7STM1PZNQljCpy6FxKbUCkejO2sG0J2URcTC8IAfsC9YeK-iKDJ7SXGT_1Kso9g7vdtRF0dpahYJZjWP/s320/IM000211.JPG" border="0" /></a><br />Opening up the transmission for inspection (btw, don't follow the disassembly instructions in the Chilton manual for this, it was totally wrong). Also, the input shaft has to be removed for special machining in order to couple it with the electric motor (a detail for later).<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilEQ-i31LCIkZ22CS9plh8TJl5qTn46ojCcNChiRVj-Ip8jBDRo4TPx1Yu82qogHCTnnvXBOZ69vjsy2nuf40L30NHKHIV7nxZ3ffKWIjVds4eK07rRwnT1dRRDj779YnZ5QJSQGMyEzQa/s1600-h/IM000206.JPG"><img id="BLOGGER_PHOTO_ID_5276930666809867330" style="FLOAT: right; MARGIN: 0px 0px 10px 10px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEilEQ-i31LCIkZ22CS9plh8TJl5qTn46ojCcNChiRVj-Ip8jBDRo4TPx1Yu82qogHCTnnvXBOZ69vjsy2nuf40L30NHKHIV7nxZ3ffKWIjVds4eK07rRwnT1dRRDj779YnZ5QJSQGMyEzQa/s320/IM000206.JPG" border="0" /></a><br />Compressing the front spring to reassemble the front suspension. With the motor gone, these are now fully extended and the parts dont fit up.</div><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjM5_MB-Yq9kFeOefdxPHyE3hC7GoFBrhPw7no1BcJVjEgDcaONfHTgGOFIVJ9RWeC9LT6xLaTPdEnAbl_YGvTdy0KxTLBWtOfY_YG_2ZEgTRXOF-BS8WSEsHcN0zCJec5-Y_f_x1PLbw74/s1600-h/IM000302.JPG"><img id="BLOGGER_PHOTO_ID_5277133283858269650" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjM5_MB-Yq9kFeOefdxPHyE3hC7GoFBrhPw7no1BcJVjEgDcaONfHTgGOFIVJ9RWeC9LT6xLaTPdEnAbl_YGvTdy0KxTLBWtOfY_YG_2ZEgTRXOF-BS8WSEsHcN0zCJec5-Y_f_x1PLbw74/s320/IM000302.JPG" border="0" /></a><br />Most of the front suspension now assembled.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgq2F2eDB4vfeR1WKC6dis1Hoq2jF-t1y6QY2yJ2upbcG96c8B3rj_sjigxr3mU97hSMhCI2w1Hu5ON3wJBP5dOMGaCepRTOVgnRKtQO36Qe0_LTfTMpcGonBdOSp6_xXqSBtETVkRvbGpR/s1600-h/IM000285.JPG"><img id="BLOGGER_PHOTO_ID_5276933185595692674" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgq2F2eDB4vfeR1WKC6dis1Hoq2jF-t1y6QY2yJ2upbcG96c8B3rj_sjigxr3mU97hSMhCI2w1Hu5ON3wJBP5dOMGaCepRTOVgnRKtQO36Qe0_LTfTMpcGonBdOSp6_xXqSBtETVkRvbGpR/s320/IM000285.JPG" border="0" /></a><br />Cleaning up the turn signal and horn switches.DrDonhttp://www.blogger.com/profile/00507851363454428274noreply@blogger.com0tag:blogger.com,1999:blog-2456430570966606735.post-79620963055183792502008-12-03T20:02:00.000-08:002009-01-03T16:02:43.225-08:00The begining of my 1954 Austin A40 Electric Car Conversion<a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGdk9-Nt1ECErc-YOFzfSXQHtiT-K7ZujFLjW7UxPLkaIXI_sDPgPaAmzG7jIMexyR5bNWgN_sH3D2Vi56CFs82jhsHR9-DwtpZ07L4-rygnhFQEV9zIZ92BDiNg2pSFfUaMfEF1T25tVz/s1600-h/Autin_a40.JPG"><img id="BLOGGER_PHOTO_ID_5275781764392815586" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 261px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhGdk9-Nt1ECErc-YOFzfSXQHtiT-K7ZujFLjW7UxPLkaIXI_sDPgPaAmzG7jIMexyR5bNWgN_sH3D2Vi56CFs82jhsHR9-DwtpZ07L4-rygnhFQEV9zIZ92BDiNg2pSFfUaMfEF1T25tVz/s320/Autin_a40.JPG" border="0" /></a><br />This blog will follow my journey in the restoration and conversion to electric drive of an 1954 Austin A40 Somerset sedan.<br /><br />The project starts in the late summer of 2008 where I set out on a project to build an electric/hybrid car, and to make things more interesting, to use a classic car as the starting vehicle. So the search was on for a donor vehicle.<br /><br />A bike ride in the country (another passion of mine) brought me by chance upon a yard with a collection of old vehicles, one of which was an Austin Somerset. The car's relatively compact size, yet ample room for batteries, and a strong frame for supporting the weight of the lead fuel, made it a good candidate.<br /><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh15IcFF_6W7kM0BcM2RNs0KV-D2WT4yVB5jwn8HcBCswVDFpzvLQj4Qihyphenhyphenz1NOB0-VXLUWieIHqhWdCQvALe34K9_o7RIuU5dQZGQAo9G8y0_dIxizqwwpAj-xILTZgfp_1hPSqIRODhRx/s1600-h/Picture+001.jpg"><img id="BLOGGER_PHOTO_ID_5275794357015698962" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 213px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh15IcFF_6W7kM0BcM2RNs0KV-D2WT4yVB5jwn8HcBCswVDFpzvLQj4Qihyphenhyphenz1NOB0-VXLUWieIHqhWdCQvALe34K9_o7RIuU5dQZGQAo9G8y0_dIxizqwwpAj-xILTZgfp_1hPSqIRODhRx/s320/Picture+001.jpg" border="0" /></a> The deal was made with yard owner and the car was delivered to my garage. (Note the garage is not insulated or heated, and I live in Winnipeg, Manitoba Canada. So its cold in there right now, but gives me the chance to start this blog. Hence, this first post will cover the last few months.)<br /><br /><br /><br /><div><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKecmn6gdH0u38Oe-bW4Tx0fPCKYGbxFxY5kvp_jLp46SOFvnFEG23E0R_N3VG6TLy0QkJdwh1ETNIqFSsODn-WtJZcpRr5AwFq4b0RkujmA22YK3CPxRbqxfYarLEFBZiGOxNnAjW6nPa/s1600-h/Picture+005.jpg"><img id="BLOGGER_PHOTO_ID_5275796168689315138" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 214px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjKecmn6gdH0u38Oe-bW4Tx0fPCKYGbxFxY5kvp_jLp46SOFvnFEG23E0R_N3VG6TLy0QkJdwh1ETNIqFSsODn-WtJZcpRr5AwFq4b0RkujmA22YK3CPxRbqxfYarLEFBZiGOxNnAjW6nPa/s320/Picture+005.jpg" border="0" /></a><br />... and the restoration work begins. Many things are rusty and water damaged. The car had been sitting idle outside for well over 20 or 30 years<br /></div><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEji21Qq5GsMOS7YV1hyphenhyphenViUmB7lFjCw-8H3zizDQX7zFTT64tH_6mv0_9C7Qe-WIMmb-ik9JIf_GrdOGk3AMYQAFzgnaammgEWUGYvEhBLt38Li_1k8wqG1LYmGw6VZd6740_MQOQvzvfcAl/s1600-h/IM000115.JPG"><img id="BLOGGER_PHOTO_ID_5275811268706096658" style="FLOAT: right; MARGIN: 0px 0px 10px 10px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEji21Qq5GsMOS7YV1hyphenhyphenViUmB7lFjCw-8H3zizDQX7zFTT64tH_6mv0_9C7Qe-WIMmb-ik9JIf_GrdOGk3AMYQAFzgnaammgEWUGYvEhBLt38Li_1k8wqG1LYmGw6VZd6740_MQOQvzvfcAl/s320/IM000115.JPG" border="0" /></a><br /><br /><br /><br /><br /><br /><br /><br /><div></div><br /><br /><br /><div>Many of the front body parts are bolted together, where most bolts can be loosened with generous amounts of liquid penetrant. Still many simply end up snapping off.<br /><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUKRwB2ohE2BfLgPcXreN9B9UojESUZFOZTy2-Jl2qD5NS748jiK43xedaTJSUKSxyof0oWp0b5F1arFFjmRfkWj-OcI9Jey-BdWir-SLep_kH3rvIWKczl_VuZx7f5t5Jjz63uJap7q3X/s1600-h/IM000119.JPG"><img id="BLOGGER_PHOTO_ID_5275813157732755330" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUKRwB2ohE2BfLgPcXreN9B9UojESUZFOZTy2-Jl2qD5NS748jiK43xedaTJSUKSxyof0oWp0b5F1arFFjmRfkWj-OcI9Jey-BdWir-SLep_kH3rvIWKczl_VuZx7f5t5Jjz63uJap7q3X/s320/IM000119.JPG" border="0" /></a><br />A view of the column shift mechanism. It is actually seized up tight.</div><br /><br /><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjO2xpmHF11lgu-YfUFIvoogcTW5WoXii2QH7_FRQGVsdv_U07zZ7YdSMUWPwkaWSXFonySXPZopxCoVYEjQueA9JWrpoAcl72vzrZ7Uez6LxfjJ3oo5BQxqaQj2aneSURyWo5V-Rm8XiXv/s1600-h/IM000145.JPG"><img id="BLOGGER_PHOTO_ID_5276147044398887810" style="FLOAT: right; MARGIN: 0px 0px 10px 10px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjO2xpmHF11lgu-YfUFIvoogcTW5WoXii2QH7_FRQGVsdv_U07zZ7YdSMUWPwkaWSXFonySXPZopxCoVYEjQueA9JWrpoAcl72vzrZ7Uez6LxfjJ3oo5BQxqaQj2aneSURyWo5V-Rm8XiXv/s320/IM000145.JPG" border="0" /></a><br /><br /><br />The differential housing had been sitting on the ground, and consequently had some rust perforation in three places. Here I drilled out the holes, ran a tap, and inserted a bolt to plug the hole.<br /><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNAzgHTmIg-uBZTWQkZhf3PPzAfpAXrnrnxsAIvkd-nVV6eGXK4J6aQt7UM2cQt58WSBN7LT1Y5wWzdkbrTag53NxZyH7oHurqg76gClOjvQ3NsSNl6KMFfqlc2O8t2pCWn1eXaQj8bJHR/s1600-h/IM000131.JPG"><img id="BLOGGER_PHOTO_ID_5276154028100657602" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjNAzgHTmIg-uBZTWQkZhf3PPzAfpAXrnrnxsAIvkd-nVV6eGXK4J6aQt7UM2cQt58WSBN7LT1Y5wWzdkbrTag53NxZyH7oHurqg76gClOjvQ3NsSNl6KMFfqlc2O8t2pCWn1eXaQj8bJHR/s320/IM000131.JPG" border="0" /></a><br />Despite there being water in the differential, the crown gear only had a bit of bit of pitting on it.<br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSZ3n3YzIh9iteZhLnhEtZww1BfIjDfUqcNiy2rKiiMvcpzIXrLD2pkkNs2PcBYOT3S-x8PUvO1JivHu7NnLru_7wB85lgDpmIZ587J5SxSKQqj2hSe-nYApamVbIsm3j1agpWupHtXMnB/s1600-h/IM000162.JPG"><img id="BLOGGER_PHOTO_ID_5276157256228534370" style="FLOAT: right; MARGIN: 0px 0px 10px 10px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhSZ3n3YzIh9iteZhLnhEtZww1BfIjDfUqcNiy2rKiiMvcpzIXrLD2pkkNs2PcBYOT3S-x8PUvO1JivHu7NnLru_7wB85lgDpmIZ587J5SxSKQqj2hSe-nYApamVbIsm3j1agpWupHtXMnB/s320/IM000162.JPG" border="0" /></a><br /><br /><br /><br /><br />Removing the engine. All the transmission bell housing bolts are off, but the clutch hub was not sliding off the transmission input shaft. Ahrggg.<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEili1O9fBhjwxEsxtniuz5BBGb5rtRqM9q8qrzdxI2DqFqG8kAOISHm3viIQ7jHcoQuxXAOPRUvAWIfC8YXWsB1uhkv8Pz1MNo9BZ_6JzC5yrMne_LO9kFydlowmfIp06LLI3FP5PVO1qpt/s1600-h/IM000166.JPG"><img id="BLOGGER_PHOTO_ID_5276158774615900082" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEili1O9fBhjwxEsxtniuz5BBGb5rtRqM9q8qrzdxI2DqFqG8kAOISHm3viIQ7jHcoQuxXAOPRUvAWIfC8YXWsB1uhkv8Pz1MNo9BZ_6JzC5yrMne_LO9kFydlowmfIp06LLI3FP5PVO1qpt/s320/IM000166.JPG" border="0" /></a>Even the slip yoke would not slide off the output shaft, so in the end, almost the whole drive train is pulled out in one piece.<br /><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6XpT28P-0zmjumadjlizuXecqbgy8IzC2XbZNzsSL908y2S3wvCs9axjy_goK-8UmDCZtf8N74TBSfhJeUwHcMalS4hSYLcBK570vybW4eUR3FRrU3bOxk71LSplMC-2s7CbDgtDpeL74/s1600-h/IM000168.JPG"><img id="BLOGGER_PHOTO_ID_5276159681462154562" style="FLOAT: right; MARGIN: 0px 0px 10px 10px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh6XpT28P-0zmjumadjlizuXecqbgy8IzC2XbZNzsSL908y2S3wvCs9axjy_goK-8UmDCZtf8N74TBSfhJeUwHcMalS4hSYLcBK570vybW4eUR3FRrU3bOxk71LSplMC-2s7CbDgtDpeL74/s320/IM000168.JPG" border="0" /></a>As my plan is to use the transmission in my conversion, I want to separate it from the engine. Here I am driving wedges to split the two. I was able to deform the clutch assembly enough to get a wrench inside, and unbolt the assembly from the flywheel. Everything in the bell housing was thoroughly rusted.<br /><br /><br /><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1EOzs20ZRjzcw58zuZvp8t4sAwMEgy_GElc0oOEzLhDV7LgPVlUUY56EJaA6UX-QEq4t4z66rlyEkuC5lrjyTNOBmWd1wKsLYfLrOutvGR6xnswlYv5OuRD6Ay6DRnkETHThLSybE5rry/s1600-h/IM000179.JPG"><img id="BLOGGER_PHOTO_ID_5276161766195410978" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh1EOzs20ZRjzcw58zuZvp8t4sAwMEgy_GElc0oOEzLhDV7LgPVlUUY56EJaA6UX-QEq4t4z66rlyEkuC5lrjyTNOBmWd1wKsLYfLrOutvGR6xnswlYv5OuRD6Ay6DRnkETHThLSybE5rry/s320/IM000179.JPG" border="0" /></a>Similar process for removing the slip yoke with wedges and lots of hammering. Lots of rust here too.<br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyRgcB40Bu9VSczBfRIv4VW5pMGkOZtoU9YTZ0wAu2pKYnhsnuQnc_9C6Xz9xzx9FjMq2dulReJCVR4OXqMIt1TB8nNVN5tEwFzWlGc51H3FRsVDtMvo5s1a3vNEaI5JtzwC0irbIysl-f/s1600-h/IM000171.JPG"><img id="BLOGGER_PHOTO_ID_5276164107085866162" style="FLOAT: right; MARGIN: 0px 0px 10px 10px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyRgcB40Bu9VSczBfRIv4VW5pMGkOZtoU9YTZ0wAu2pKYnhsnuQnc_9C6Xz9xzx9FjMq2dulReJCVR4OXqMIt1TB8nNVN5tEwFzWlGc51H3FRsVDtMvo5s1a3vNEaI5JtzwC0irbIysl-f/s320/IM000171.JPG" border="0" /></a><br />Removing the gas tank, to make room for batteries, eventually.<br /><br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUdzDf8UGcRiKE1R8K4nAVkVa2ZX88L0oRVniKmuB3pkajCySzN0GM1ib88aAIWyxBRIEkKXv5vBG0wql1N_t3NoDQmeut_oOe4p3aWoWu3sCFhjqUFxKIPBU-6Gbj0PRbahXWEPOlDchj/s1600-h/IM000193.JPG"><img id="BLOGGER_PHOTO_ID_5276166977157470578" style="FLOAT: left; MARGIN: 0px 10px 10px 0px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjUdzDf8UGcRiKE1R8K4nAVkVa2ZX88L0oRVniKmuB3pkajCySzN0GM1ib88aAIWyxBRIEkKXv5vBG0wql1N_t3NoDQmeut_oOe4p3aWoWu3sCFhjqUFxKIPBU-6Gbj0PRbahXWEPOlDchj/s320/IM000193.JPG" border="0" /></a>Lifting the body from the frame, and rolling it out from underneath.<br /><br /><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyPcGsAVvEbzk2NGoLayasRzGoD7yf77l9fE0dyxU93_lK3WATL-M_OTDd-SPXyaNUJIrCognsVarNJQqpQ_lWfCSbPKXApRfO39UoD_kRugFGjaWvML-8sje-8DGj444rzWzN1_gYUyOQ/s1600-h/IM000199.JPG"><img id="BLOGGER_PHOTO_ID_5276167591577440658" style="FLOAT: right; MARGIN: 0px 0px 10px 10px; WIDTH: 320px; CURSOR: hand; HEIGHT: 240px" alt="" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhyPcGsAVvEbzk2NGoLayasRzGoD7yf77l9fE0dyxU93_lK3WATL-M_OTDd-SPXyaNUJIrCognsVarNJQqpQ_lWfCSbPKXApRfO39UoD_kRugFGjaWvML-8sje-8DGj444rzWzN1_gYUyOQ/s320/IM000199.JPG" border="0" /></a>The frame after a spray-on rust conversion treatment and a coat of chassis rust-paint.DrDonhttp://www.blogger.com/profile/00507851363454428274noreply@blogger.com0