..when a plan comes together.

The Battery Box

still in action..

EVDrive 37/2015 Squeaking In Silence

Big Block

First fitting of 36 cells in the front.

Framework

First I tried a 39 cell frame version. But it was a bit too big and had to be installed with a little angle. I slept a night over it and thought it was stupid.)

I had to cut the frame down to a 36 cell version.

Then I had to build ten completely different holding struts.

Looking good.)

EVDrive 36/2015 Mission control.. we are ready to go.

Missing In Action (the pilot)

Today I had to remove the motor again.

Which was not to funny..

The reason was an opening clutch but not opening (Thai-style).

Ok. The clutch is opening but the motor was looked to the gear shaft. What can that be...?!

I remembered that I found it not so intelligent, not to have a drawn or whatsoever profile in the bronze bushing for the lubrication. Even I do not know if it is bronze.

So my guess was pretty soon, the bushing is blocked.

Luckily I had a pilot bearing, an open machine shop around and enough room in the motor adapter. (and 30.-€ cash.)

It was pretty much a nightmare to bring everything together again, BUT twelve hours later it was done.

Everything is together again, installed and clutching.)

EVDrive 35/2015 The Very First Time

First Spin

Fun Factory

You Are Here

I decided to do a complete new motor-gearbox mounting to the frame.

It is a little bit complicated to find the "exact" position with a flying piece at about 200 kg and no real references in all three dimensions. But this is a homemade problem so I have to fix it.

Clutch housing mount passenger side was not right.

The clutch housing at the driver side had to be adapted.

Weather Report

I'm stuck in winter weather and some braking details.

more to come soon..

Wrong Is Right

This spacer ring has actually two different sides.

The side with the right angle to the shaft and one without.

Using the wrong side makes it right.

Sing Halleluja

Twenty Months Later

A too small spacer ring...

Right But Wrong

Believe it or not. The parts are "ready"

Everything comes together very nice, but the missing dowel pins...

They also forgot them on the flywheel. 

Also the adapter plate is not in the size of the bell housing.

But we are coming closer.

Today I will bring it back to them and we will see what will happen..

Eccentric People

My machine shop does not get it to use fitted bushes or register pins to mount the adapter plate to the bell housing...

"try it and then we look..."

EVDrive 31/2013 Half Turn - Double Force (How to double the spring press...

How to double the spring pressure in a WarP9

It's long, it's tough. it's boring....but I had to figure out how to do it.

And all the failures show how it does not work.

Paper Progress

At the end of this week, he said...

Laser Deposit Welding with Powder

 Better wear resistant ball bearing surface finish than the original drive shafts.

EVDrive 30/2013 Overview 2/014

Progress'14

It finally goes on...

                                                stay tuned.

Triple H

We have made the H (historic classic car) report.

Gearbox Input Shaft

I thought I could do a quick change on the gearbox input shaft.

I was wrong but in the end it is done.

Changing from a 21 to a 10 spline shaft.

The 17 open bearing rollers hold with some grease inside the shaft.

It is the right decision to use my accumulated FJ40, BJ40 and HJ45 parts assortment from 1978-84 in this project.

But nothing fits straight together.

It is so much easier to convert just a driving car.

Table Top Measurement

For the perfect adapter plate.

Twice Cut And Still Too Short

The exact fitting to the housing mounts is a little bit tricky and takes more time.

I had a 13.2 mm shift to the clutch housing mounts in my basis plate.

Adapter Prep

Preparations for the Adapter Plate measurements.

The gearbox needs to be empty.

Also the clutch housing.

Just a mock-up motor and plate to see how it comes together.

Happy Divorce

 After 35 years happy marriage we also have a happy Divorce.

The motor mount side.

The two clutch housing mounts to the frame are missing. So I have to build them...

 

Passenger side is still missing.