FVEAA Forums
Member EV Projects => Conversion Projects => Topic started by: todd.dore on May 15, 2008, 01:29:56 AM
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Many of you know that I'm currently conveting a gas car to an EV. Now that we've secured a nice garage to use, I would like to invite any FVEAA member or guest who is interested in seeing how a conversion is done to come along and help out.
The more hands, the merrier!
Not only would additional hands be nice, I could also use some help with technical issues - installing the main battery box, the manual transmission, mating the trans onto the electric motor, etc.
This Saturday morning (5/17), and every Sat. morning, I'll be at the garage for a few hours to work on the car. Come one, come all! If you're an 'EV expert' or a beginner, everyone is welcome!
I'll bring along some breakfast treats (donuts and coffee) and will be there at 9am. Wear some grubby clothes that you don't mind getting dirty, and be prepared to learn, laugh, and work on an EV conversion! The car is a 2001 VW New Beetle that will make one sweet conversion when it's done.
The address is 2820 S. Highland in Berwyn, IL. The garage is located towards the back of the property.
My cell phone is 708-307-1399 in case you need to get in touch with me.
I look forward to seeing you on Saturday morning!
-Todd Dore
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This weekend isnt good for me but I live near by. Definitely will take you up on it.
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Hey Todd, Count me in for some help! i suggest you post your intended tasks for a given Saturday ahead of time, perhaps Thursday night, so people can see if their skill sets/desired learning mesh with the tasks at hand. Great idea to invite us all to help/learn, thanks!
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Last weekend the 1st inaugural electric bug conversion session went well - thanks to all who attended (Matt, Wayne and Jim).
This Saturday 5/24/08 we're doing it again - 9a-noon. The address is 2823 S. Highland in Berwyn (that's the correct address).
We plan on measuring/fabricating the motor mount for both the tail shaft and the torque rod. We will also be fabricating a support across the front of the car to support the last battery box. It would be great if anyone with metal fabrication skills (hint - Wayne!) would come out for this week's session.
We'll have coffee, donuts, and juice. Please wear grubby clothes because we do get a little dirty.
Come one, come all - what else would be a great way to kick off the Memorial Day weekend but to see how EVs are built!
Please call with Qs - 708-307-1399
-Todd
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I wont be available until after 1 PM. If you plan on doing any other work during the long weekend let me know. I have an engine lift if you havent removed the engine yet.
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Eddie:
I might do some work later in the weekend as well. How about if you give me a buzz? 708-307-1399
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This Saturday will be the 3rd one for the Elec Bug conversion.
Last week's session was another successful adventure! My thanks to George, Steve, and Wayne. We mapped out the motor mount for the passenger side of the motor, aligned the motor/trans assembly better for final fitting, and set the specifications for a cross-bar to mount the front battery box. This front mount will also act as an anchor for the Plexan (sp?) board that all the controls will mount to.
On Memorial Day I was also able to do final sealing of the main battery box and removed the rear springs. Since we're adding over 1,000 lbs. to the middle and back of the vehicle with the batteries, we need heavy duty springs.
Come on down to 2823 S. Highland in Berwyn at 9a on Saturday morning, 5/31/08. Free coffee and donuts for your time. Learn how an EV is built!
For this week's session, Wayne will bring both the passenger side motor mount along with the cross bar for installation into the car. We can also mount the front battery box, and shape and cut the Flexan for mounting the main components.
It's always fun and interesting - so come on out and be a part of EV history, right here in Chicagoland!
My phone is 708-307-1399 if you need to get a hold of me.
-Todd Dore
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Next Saturday, 6/7/08, will be the 4th Saturday for the conversion of Electric Bug. Thanks to all who have helped so far! George, Matt K., Jim D., Matt R., Steve Clarke, and Wayne (please forgive me if I've forgotten anyone).
We've achieved so much - the engine and trans are mounted, and we're ready to continue.
Next Saturday we will be installing the front battery box with a new mount fabrication, tack-welding the main battery box to the frame of the vehicle, and start the installation of the flex tubing underneath the car for the 2/0 cables. I've also ordered most of the main components and should have those shipped within a week or two.
So come on down to 2823 S. Highland in Berwyn, IL. As always, I'll provide coffee, donuts, and juice. We begin at 9am and usually go until noon or 1pm.
All are welcome, so come on by to see how an EV is built!
-Todd
(708) 307-1399
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Last Saturday was another success - thanks to Wayne for coming by to help out.
Next Saturday 6/14 is #5 and we are looking forward to continuing to mount the front battery box and a Flexan board to put all the electric components.
There are a number of parts which should arrive in the next 2 - 8 business days, so we can start mounting and measuring things.
Please come by and see how a real EV is converted! Breakfast juice and munchies will be provided.
2823 S. Higland in Berwyn, IL from about 9a - early afternoon.
Any questions, I can be reached at 708-307-1399.
We look forward to seeing you there!
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Tomorrow 6/21 will be Saturday #6 for the Electric Bug conversion. Thanks to those who participated last week - Wayne and Charles.
We finished installing the front battery box and finished up all the transmission links. Everything works - I can spin the motor and shift all the gears - clutchless!
Next week we will shape a template for the control board. We will also be shaping a template for a sub-board which will go below the control board. I have all the major control components in except the power steering pump.
Come on by to see how a true EV is converted. We'll supply juice and coffee.
9am at 2823 S. Highland Ave., Berwyn, IL.
Please call me at 708-307-1399 if you have an questions.
Hope to see you there!
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This Saturday 6/28 will be session #7 for the Electric Bug conversion.
Last week was a resounding success! We had a record attendance! Thanks to all who stopped by to help out.
Next week we will be finishing the main and secondary component boards and mounting those into the car. The Lexan will look very nice!
Come on by to see how a real conversion is done.
2823 S. Highland Ave., Berwyn. We start at about 9am and continue to early afternoon.
I'll provide breakfast drinks.
Please call at 708-307-1399 if you have questions.
See you there!
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This Saturday - 7/5 - will be session #8. About 2 months of the Saturday morning conversions!
Last week we finished the double-decker mount for the major components. Thanks to all who helped out.
The batteries are in! Next Saturday we will cut the cables and start to crimp some lugs onto the cables to wire it up.
Come on out - OJ will be provided, and see what an EV conversion is all about!
2823 S. Highland Ave. in Berwyn. We will start at about 9a and go until 1 or 2pm.
Have a good 4th of July Holiday and see everyone there!
-Todd
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Folks -
I've unfortunately come down with a nasty bug and spent the morning today (July 4) in the ER at Rush-Pres.
As such, I cannot make it to the work session tomorrow for Electric Bug. So, the session is cancelled. I apoligize in advance to anyone that has to re-arrange their schedules and appreciate your support.
My wife, Maribel, will come by the garage tomorrow morning at about 9am to let anyone who shows up know that our session has been cancelled. She will also leave a note on the garage door to that effect.
Sorry about this - I'll get better and we can continue next Saturday 7/12/08.
-Todd
708-307-1399
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I'm back in form and beter than ever. This week I've received the DC-DC converter, the ammeter shunt, the main Anderson disconnect switch, and the power steering pump.
This Saturday 7/12 let's do it again at 9am, 2823 S. Highland Ave, Berwyn.
Come one, come all - free orange juice!
See how an EV is built.
This weekend we will measure and cut the 2/0 cable for the back battery box.
Call if you have questions -
Todd 708-307-1399
See you there!
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Here we are, another Saturday with an EV conversion!
Come on over and see how cars are converted to EVs.
We didn't get to cut the cables last week, so let's work on that this Saturday, 7/19/08. 2823 S. Highland Ave., Berwyn, IL. The garage is located near the back of the property.
Come on out for some EV fun!
-Todd 708-307-1399
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I think that we're up to session #10 for the Electric Bug conversion!
Come on out to see how a conversion to 100% electric is done!
This Saturday (tomorrow), 7/26/08. We'll start at about 9-9:30am, and go until early afternoon.
This week we will continue with the High Voltage wiring - it is about 2/3 complete, and we need to drill some 1" holes in the battery boxes for the 2/0 cable. The cable will also go into a protective plastic hose underneath the car.
Come on out and have some fun learning. It will be nice to see some familiar faces again! (you know who you are!)
We will provide orange juice.
2823 S. Highland Ave, Berwyn, IL
708-307-1399
-Todd
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This Saturday will be session #11. That's 8/2/08, and we will start around 9am.
2823 S. Highland Ave., in Berwyn. Come on out to see how a conversion is done.
We're about 2/3 of the way to the finish line - and going strong!
Thanks to Matt for helping me out last weekend.
This Saturday we will be finishing up all the HV cabling in the motor compartment, and perhaps start on all the LV wiring. So, we'll be doing some cable cutting, crimping, and insulation with heat-shrink. Ken will be testing the simple charger that he will bring to make sure the batteries can take a charge.
Call 708-307-1399 if you have questions.
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Todd - did you guys get to do the charger test yesterday or did we need to do more HV wiring?
I've had a blast on the four occasions I've worked on this conversion. Everyone should come. Todd has the car set up nicely in a spacious garage and there are LOTS of great lessons learned even if you've done another conversion. Each one is a little different and no two people have the same challenges.
Also, if anyone has a wiring snake they can bring that might help with pulling the LV wiring through the conduit we've rigged up that would be really helpful.
Finally - I haven't looked up the stats yet but after talking to some of the guys here at work, I'm thinking that our best route for the BMS LV wiring (16 pairs - 32 total wires @ up to 1A each) may be to split current across multiple wires and use standard telco 50-wire bundles. If we use two bundles, we can use thee wires per pole, or up to 1/3 A per wire. If we can squeeze three bundles through, we could make that four per pole, making it up to 1/4 A per wire. Does that sound feasible to you guys? Does anyone know a better way?
Matt
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Matt:
I very much appreciate your help and the advertisement - but seriously, the sessions are always informative and a lot of fun.
There still is some HV wiring up front to be done and Ken is coming tomorrow with the charger to test. However, I have installed the main disconnect, so we can work on HV up front while still charging - with the main disconnect turned off.
I did get some wire through the flex hose, and I'll tell you how if you show up this weekend.
Also, I just got the springs today - hopefully they will fit! Things are really coming together...
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Sorry I couldn't make it -- I was busy at iPhoneDevCamp this weekend. How did it go?
Matt
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Looks like we're up to Session #12 this Saturday. Come on down to 2823 S. Highland in Berwyn, IL to see how an EV is converted!
Last Saturday was the most productive EVer. We got Ken's charger hooked up and running, the HV system finished, and started the LV.
Sadly, the coil springs are too big and don't fit, so I sent them back to re-do.
In the meantime, this weekend we will be installing some air bags for the rear coil springs and hopefully they will fit and we will inflate them. Supposedly these can take the extra weight.
Also, I'll need some help sealing a leak in the high pressure line for the power steering and then filling the resovoir.
Finally, we can continue to do the LV wiring. I've completed the wiring for the ignition key activation, the 12V terminal strip, the brake pump, and the power steering pump. Next comes wiring the water pump for the controller, filling the water/antifreeze, wiring the controller, and finally the DC-DC converter. With a productive session we may be able to get much of this done.
The batteries are about 95% fully charged and I replaced the warped rotor this week. So, things are looking good!
Come on out and be part of the fun! 708-307-1399
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Todd,
Have you figured out how to get your tachometer to show correct rpm?
It looks like Zilla can be set to give you either standard 4 cylinder or 6 cylinder tack signal.
Miodrag
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Miodrag -
No, I haven't started on that one yet. This might come up in the next 1-2 weeks. I might call you for some advice.
Thanks!
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This Saturday is session #13 - it will be a lucky 13!
The low voltage wiring is near completed. The PackTracker, Controller w/pot box, and analog meters need to be wired up. Also, if we could get some of those obnoxious alarms to shut off I would be really pleased. All of this should be able to be completed in 1 good day's work with a little help from friends.
Thanks to Larry, Lynn, and Wayne for showing up last week. We installed the original springs back in the car with the AirLift balloons, and they seem to be working great. With the car lowered to the ground there is definitely room to bounce on the springs! One issue is that the middle battery boxes hang 5" off the ground, which is 1" lower than I would like. I may have to deal with that one later.
We also finished the HV wiring and fixed all the leaks in the water pump system and power steering.
Come on out this Saturday, 8/16/08, starting at about 9am. I'll be there until about 5pm. Anyone who is around for lunch - I'll buy some sandwhiches.
It's always a good time and we may just get Electric Bug on the road!
2823 S. Highland Ave., Berwyn
708-307-1399
See you there!
-Todd Dore
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Good news - Electric Bug is on the road!!!!
Today we fixed most of the electrical problems (a special thanks to Ken - he did all the diagnosis and prognosis on this baby), and took the car around the block.
Thanks to Ken and Larry Houle - we put in a long day today (I took the day off work).
Next Saturday, 8/23/08, will be session #14. There are some more things we need to do, such as finishing the outside plug (Larry is doing this), installing the back seat, and making a cover for the back battery box.
We could also do some wiring harness fixes, and test the wires to the instrument panel to cut off the warning lights and bells. Getting the tach to work would be nice as well.
Finally, a change of the M/T gear oil fluid would be proper.
Come on by to see all the fun! 2823 S. Highland Ave., Berwyn, IL. 708-307-1399 (Todd).
This will be the last session for about 1 month, as I will be getting an operation next week and need to recover during Sept.
Hope to see you there...