Oct 31: All Batteries

Oct 31, 2007, Tasks Accomplished:

• Installed fuse in front pack
• Crimped final ends on long runs of #2 cable
• Wired front batteries
• Got low pressure power steering hose installed
• Filled and tested power steering system
• Wired DMOC
• Got PotBox throttle working and wired
  

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Oct 30: Controller Wires

Oct 30, 2007, Tasks Accomplished:

• Reread controller manual and wiring diagrams
  
• Sorted controller (DMOC) wiring loom
• Got high pressure power steering hoses installed
• Went to GF
  
• Got another large fuse, power steering fluid, and work light
  

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Oct 29: Low Voltage Wire

Oct 29, 2007, Tasks Accomplished:

• Decided to order charger from a guy outside Seattle, get EV running, weigh it, then go to Seattle and wait for charger
• Wired
• Finished wiring air vacuum pump
• Ordered new charger
• Installed vacuum hoses on brakes

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Oct 28: No EV Work (pic)

Still goofed with paint, and talked through possible options for the charger. A guy outside Seattle makes one...



Went to check out my dad's old cabin that I bought from him.



For a very good price!



Thank you dad!

Oct 27: Saturday (pic)

Did nothing on the EV, just worried about the charger.



How is it that we could we be informed now, two and a half months after placing and paying for the order, that some guy sold us something he doesn't have and can't get.



And a piece that is absolutely essential for the success of the project.



I painted my car to amuse myself, and my dad and I went to a Halloween party.

Oct 26: Charger Help?

Oct 26, 2007, Tasks Accomplished:

• Emailed about a charger
  
• Emailed more about chargers, thanks SEVA people
• Called about charger
• Drove back
• Started low-voltage wiring
• Reinstalled power brake air pump with proper feet and hardware
  

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Oct 25: Charger Email!

Oct 25, 2007, Tasks Accomplished:

• Cleaned up tools and garage
• Uninstalled power steering vacuum pump
• Measured for screws and wire
• Build electrical wiring table
• Went to GF for shopping and email
  
• Got email from ElectroAutomotive that they cannot supply the charger they promised (that ruined my day!)
  

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Oct 24: Plexiglass

Oct 24, 2007, Tasks Accomplished:

• Finished plexiglass mount for electrical
• Glued two pieces of plexiglass together
• Painted and installed vacuum canister and mount
• Worked on bed to hood wiring
• Made 12V battery negative to chassis ground and hooked up
• Tested some body electrical (lights, horn, etc.)
• Started vacuum routing
  
• Made shopping list for GF
  

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Oct 23: Controller In

Oct 23, 2007, Tasks Accomplished:

• Installed fuse in middle of bed-battery pack
• Sized rear tires, maybe 225/65R15, load 96
• Installed bracket and tray for controller
• Installed controller
• Made bracket for vacuum brake canister
• Installed front batteries and started to wire
• Started on electrical plexiglass tray for low-voltage connections
• Worked on bed to hood wiring
  

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Oct 22: Got Shrinkwrap!

Oct 22, 2007, Tasks Accomplished:

• Finished bracket support for controller
• Painted controller support and brace
• Received shrink-wrap (another idem we ordered from ElectroAuto, did not receive, and eventually bought from someone else)
• Removed all battery cables and applied shrink-wrap
• reinstalled battery cables
• Connected power steering hoses
• John put on old rear tires
• Mounted air pump for brakes
  

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Oct 21: Drove back

Drove back from Spokane. The quick weld fix on the rusty exhaust bracket failed on the return drive.

Oct 20: In Spokane

Was in Spokane visiting relatives.

Oct 19: Torsional Support

Oct 19, 2007, Tasks Accomplished:

• Made support for front battery tray to add torsional support
  
• Drove to Spokane to see my aunt
  

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Oct 18: Reinstalling

Oct 18, 2007, Tasks Accomplished:

• Installed Driveshaft
• Picked up tires in GF
• Installed frame brace
• Zip-tied air suspension hosing
• Fashioned two brackets for rear brake lines (needed to move 1/2" because of air suspension)
  
• Welded and measured rack for controller

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Oct 17: Air Is In!

Oct 17, 2007, Tasks Accomplished:

• Installed and tested air suspension
• Finished battery hold-down
• Primed and painted battery hold-down
• Installed power steering pump, resivor, and front batteries on new battery tray
  
• measured for controller
  

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Oct 16: Air Suspension

Oct 16, 2007, Tasks Accomplished:

• Welded brackets for all-thread for front battery hold-downs
• Welded mounting for power steering
  
• Air suspension was delivered today
  

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Oct 15: Front Batteries

Oct 15, 2007, Tasks Accomplished:

• Cut and welded tray for front four batteries
• Installed clutch slave and tested
• John worked on speaker covers
  
• Painted front battery tray
• Started to cut and weld front battery hold-down
  

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Oct 14: Relax

Watched football, then drove back from Bozeman. That 1970 is doing well getting me around!

Oct 13: Football

Drank beer and watched football with Blake, my good buddy from college. Fun times!

Oct 12: Motor in!

Oct 12, 2007, Tasks Accomplished:

• Moved truck out of garage
• Bolted motor mounts to motor
• Put motor in
• Tightened motor mounts to motor, motor mounts to frame, and tranmission mounts
  
• Went to Bozeman to hang out and drink beer with Blake.

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Motor is in, and it fits!

Oct 11: Motor Mounts

Oct 11, 2007, Tasks Accomplished:

• Left GF
• Bolted transmission to motor with proper hardware
• Cut pieces for motor mounts
• Drilled motor mount holes
• Tack welded motor mounts
• Tested, then welded motor mounts
• Ground and painted mounts
  
• Welded exhaust hanger on BMW
  

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Oct 10: Motor to Tranny

Oct 10, 2007, Tasks Accomplished:

• Got loctite
• Mounted flywheel
• Mounted clutch and pressure plate
• Mounted motor to transmission
  
• Measured for metal for engine mounts, under-hood batteries, etc.
  
• Went to GF for metal, shrink-wrap online, hardware for motor mounts, hardware for transmission to motor
  

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Oct 9: ADAPTOR PLATE

Oct 9, 2007, Tasks Accomplished:

• Fixed lawnmower
• Ordered fuses and proper fuse block
• Ordered circuit breaker
• FINALLY RECEIVED ADAPTOR PLATE
• Redrilled holes on adaptor plate
• Removed clutch and flywheel
• Mounted Flywheel to electric motor
  
• Built puller for spline shaft
• Need to get loctite tomorrow
  

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Finally got the adaptor plate for ElectroAutomotive. It was supposed to be delivered a month after we ordered, and we ordered and Julie and John payed in full on August 13th. This has been holding us up, as it is needed to put the motor in. Only after we get the motor in can we place the controlled and the batteries and start to wire. We have it now, though, so we can get to work.

Oct 8: Conduit

Oct 8, 2007, Tasks Accomplished:

• Emailed about fuse sizing and circuit breaker sizing
• Worked on conduit from bed to engine compartment
• Installed fuse
  

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Oct 7: Stayed in GF (pic)

Oct 7, 2007, Tasks Accomplished:

• Bought fuse and junction box
• Emailed about fuse sizing
• Started copying these daily lists into computer
• Fashioned 240VAC 100A fuse as temporary solution

The temporary fuse for the rear battery pack. Will get fuses rated for 600VDC, but for now we will use this. Really, is installed just in case we short out something by dropping a wrench, other than that, it has no real purpose.

Oct 6: GF Shopping

Oct 6, 2007, Tasks Accomplished:

• Went to GF
• Bought junction box and plastic grates
• Looked for fuses online
• Uploaded photos
  

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Oct 5: Start High Voltage

Oct 5, 2007, Tasks Accomplished:

• Wired batteries in bed
• Bought conduit, nuts, bolts
• Put rear suspension back together with old shackles
• Ordered air suspension
  
• Looked and circuit breakers and fuses online
  

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Oct 4: Shackles Still

Oct 4, 2007, Tasks Accomplished:

• Went to GF
• Bought new bolts for new spring shackles
  
• Priced air suspension
• Emailed
  

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I had originally planned on adding air suspension to the rear, but was trying to get by with modifications to the existing springs. Looks like we will add air suspension also, as there is quite a bit of weight back there.

Oct 3: New Spring Shackles (pic)

Oct 3, 2007, Tasks Accomplished:

• Suspension work
• Started to cut new rear spring shackles
• Went to GF for new jacks and stands
• Ground new shackles
• Drilled shackles

Did not take any pictures of the shackle construction, but did take a picture of the neglected transmission and the Seattle-like weather.

Oct 2: Finish Hold-down

Oct 2, 2007, Tasks Accomplished:

• Finished welds on battery hold-downs
• Revamped suspension by swapping the order of the leafs in the rear packs
• Cut down all-thread
• Welded bolts on all-thread and installed
  
• Spray painted channel-iron runners
  

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Oct 1: Batteries in Bed

Oct 1, 2007, Tasks Accomplished:

• Moved batteries off rubber bed mat
• Installed rubber mat in bed
• Installed bed battery tray in bed
• Moved 36 batteries into position in bed
• Installed new battery hold-down
• Installed new all-thread, bolts, and nuts
• Cut two long steel runners, welded, and installed
• Drilled two cross-runners and installed
  
• John worked on speakers
• Replaced driver's side rear wheel cylinder
  

Flickr Slideshow