THE GRAND TO DO LIST
adapted by Tim Moore
for club project Porsche 944
DEFINE A NEED ---X
SELECT A VEHICLE---X
SELECT A DRIVE SYSTEM--X clutchless EV Batson, motor WARP 9
CONVERSION PREPARATION “A”
1. degrease and wash the car inside and outside especially the underside--rust???
2. spray WD40 fasteners
3. purchase shop manual (not just CHILTON the official shop manual)
4. measure ride height both front and back wheels from the ground to the top of the
wheel arch
5. weigh the vehicle before removing any parts. Curb weight full of gas with driver.
6. SUSPENSION--ERIC--X
CONVERSION PREPARATION “B”
7. sketch an accurate “system layout” including placement of :
7a. drive motor, transmission, differential ---Jim Dawson, Joe Downing others
7b. controller,contactor, fuse, DC/DC converter, pot, shunt: bench set-up Need 7a
7c. vacuum brake pump and reservoir with relay: bench set-up Need 7a
7d. charger, circuit breaker, fuse : prefer in passenger compartment, fuse N/A
7e. low voltage system, meters V and A, ignition, fans
7f. battery boxes front: dependent on 7a
7g. battery boxes rear
7h. analyze the “system layout” for adequate cooling, side to side weight, front to
back weight, noise, cables, easy access for diagnosis and repair
ICE REMOVAL: note after clutchless system done 7a
8a. make sure all fluids are drained , of course brakes stay.(note gas tank can be filled with water)
8b. label all wires and hoses including the throttle: label both sides easier for selling and installation
8c. put all small parts into ZIPLOC bags and label them
8d. remove or condition the interior area for battery boxes
8e. organize parts to be sold, donated or scrapped (NOTE: keep all spare parts OEM parts especially fasteners and fuses, very helpful)
9. determine axle weight--see website
10. isolating the transmission--see website--Jim Dawson, Joe Downing,others
11. the adapter plate---see website--Jim Dawson, Joe Downing,others
12. motor mounts---see website--Jim Dawson, Joe Downing,others
13. CONTROLLER
13a. ensure no conflict with other devices i.e. hood
13b. ensure easy access for diagnosis and repair, hinged for easy removal
13c. if air cooled ensure adequate ventilation
COOLING SYSTEM-- no air
THE “GAS” PEDAL
14a. determine placement for throttle pot, ensure no constriction and easy access
14b. build a mounting plate for throttle pot
14c. modify throttle cable for correct length
14d. install throttle bracket
14e. test throttle pot to ensure full range of pot, smooth running cable
EXISTING ELECTRICAL SYSTEM
15a. make a list of existing component to keep and those to remove (caution do not remove unless necessary and certain) see website
15b. power up vehicle auxiliary to determine what systems work and not
15c. design and construct EV control unit for supplementary systems--see website
POWER STEERING--NONE X
POWER BRAKES--? copy Emde design in 1994 Ford Escort
CABIN HEATING--anyone
or Eric wear a good coat
BATTERIES
16a. estimate battery pack size, type, maker, X Bob Batson 12v x 12
16b. determine battery safety, fuse, circuit breaker, connectors, venting
Bob Batson
BATTERY CHARGING
17a select a battery charger X Bob Batson
17b. install and set-up the charger--prefer inside passenger compartment
BATTERY BOXES#
18a. select a battery box material under hood
18b select a battery box material inside passenger compartment
18c build wooden boxes the size of the batteries adding an extra inch to the top, and 1/2 each side for thermal maintenance and suspension/cushion
18d build battery boxes under the hood
18e build battery boxes inside passenger compartment
18f install battery boxes under the hood
18g install battery boxes inside passenger compartment
18h install appropriate venting--note simple computer fans work well
BATTERY CABLES
19. design and fabricate??? Bob Batson
CHARGING PLUG AND ACCESSORIES
20.
BRAKES
21
SUSPENSION
22
