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Monday, 28 January 2013

It's Done


I have finished the frame and box so here it is out from under the car this shows the upper frame support with the extension arms which bolt back to the spare wheel well. There are inner pieces of metal which bolt inside the wheel well for additional strength 


From a different angle you can see the inner metal strengtheners one being mouldered to the round base of the wheel well  


Top view


had to cut the forward support holes to allow the frame to swing down for battery box removal  


Have welded two more angle iron support pieces on the base of the box support 



This shows the passengers side inner strengthener 


And the curved drivers side strengthener 


Frame with box 


Using some 25 x 25 mm angle with 8 mm all-thread for holding down battery box 


This is the front hold down clamp


Just showing all-thread I have welded the top nut and thread 


Just adding the brace for the drivers side support bar which clamps back to the wheel well









Cheers 

Monday, 21 January 2013

Are we there yet?


Well the frame to house the battery box is almost complete these photos will require you to play twister with your head. the bracing is done and just tacked together as the whole structure now has to get engineering approval and I anticipate a few changes will be required. The box full of batteries is required to withstand a 20 G frontal impact and a 10 G side or rear impact and remain in-tacked and not break away from the car. I found I just had to make the thing as I couldn't describe or draw it well enough to get the engineers specifications.


Ok here we are looking up at the support which in turn is welded to the angle iron bolted to the extended seatbelt bolts you can also see the strut on the right which bolts to the body.


Camera angled up a bit more you see the support tacked to the angle 


This dog leg brace will need to be made in a thicker material 6mm not 3mm with a diagonal drace welded behind 


Again the dog leg is required to clear the box


The other side brace again different because the under body of the car is not symmetrical 








Hows your neck?
Thanks for looking, Rob

Saturday, 12 January 2013

That BOX!


After 3 different models and 2 attempts to construct I have completed the battery box, it will hold 24 Thunder-sky 100 amp batteries laying on edge providing me with half of the final pack voltage of (144 Volts)


Steel Rivets used as the Registration inspectors won't accept aluminium 


Part of the pivoting rack for the box. This will drop down and allow the battery box to slide out as a cartridge so I can use it on my yet to come E-Boat/party pontoon but still leave a second 72 Volt pack in the car for driving


Box nice and snug in rack





This shows the box about to be slid up into place 


And sits up nice and neat


not a lot of room between the shocker mounts 


And the clearance at the front of the box, needs to accommodate the park brake cables 


Cut 45 mm off the hight of the box  


Looking at where the back seat bolts in you can see the inspection hole for the old fuel tank pump just above and too either side to the rear are the seat belt mounting bolts I have tapped the tread to a larger 12 x 1.75 mm and put new high tensile bolts in that are 20 mm longer so I can bolt a mounting system under the car for the box 



The original bolts tightened flush with the nuts now 20 mm of thread protrudes for mounting bracket I have almost finished the mounting system however I can't get the camera far enough away from the car to get a picture!











  Cheers

Wednesday, 2 January 2013

40 C in the shed I'm out here


Early start this morning because of heat however Controller, Main Contactor and Auto Precharge resister installed. I had good intentions to keep going but an early start tomorrow morning is on the list. 

Now What is This Korkie???

Adding a second story for the controller


This will allow the main contactor to sit under the controller



Then I can use short brass buss bars for some of the connections


Like This


Next the precharge resistor to protect the controller


Looking like this


and put back in the engine bay

\

Next project hot water, showing the electric water pump from a 2005 VW $20 from Ebay


Cheers


Tuesday, 1 January 2013

Peripherals, small update


Had good intentions today but it's new years day I'm in recovery mode and it's to dam hot in the shed so only a couple of things done. The first in was a check to see the braket for the gear linkages and cables fit all ok.


Next a small braket and cable holder then mount the Pot Box, why do the teenages ears prick up every time I say Pot Box?


That will do for today. Cheers