Electric Assist Project: E-charger (2000 Subaru Outback)

[Phantom]

I was also going to say try finding a freewheel that you could use that way if the ICE ever revs faster than the AC motor the AC will not add drag to the car.

[ShadeTreeMech]

correct me if I'm wrong, but wouldn't an instance where the engine is pulling the motor recharge his battery pack to an extent? I'm thinking take advantage of it for some serious engine braking.

[brucey]

Yes, if I did the one way bearing/sprag clutch I would lose all regen. I think I'm going to set the motor to the original 6k=7.5k rpm and see how it performs, then worry about giving it more gearing if need be.

Also, didn't have any luck finding the steel I needed today. Will have to try again tomorrow. I also am going to try to make the next plate without removing my power steering pulley. Which, while annoying, shouldn't be impossible.

However, I DID get the fuse/contactor/throttle in, so now I have all the parts ready except for the batteries. And I've also driven 20 miles with that bracket in place without issue (as expected, but it's always good to test as I go)

[brucey]

Gave up trying to find metal locally and ordered aluminum offline. When it comes it, I will be able to finish the bracket.

[brucey]

Metal came in and I started work on the bracket, didn't get as much done today as I would have liked, but it's coming along nice enough:

Once this bracket is done, I'll build 2 smaller connecting ones to connect it to the intake manifold and the other 'weight' bracket. It should be sufficiently strong.

[ShadeTreeMech]

How goes the build? I'm eagerly anticipating the rest of the story! Was trying to sleep just a bit ago, but wondering about your project kept me awake

[brucey]

The 2 main brackets are done, I plan to build 2 more supporting brackets attached to the intake manifold and connecting the 2 bigger ones out of some steel. Just need to bend it to shape. I've been driving with the brackets in place to make sure they'll be alright as far as daily driving. Happy to report no problems! No rubbing on the belt or pulley, no hitting the hood (even when starting the engine and under load)

Also ordered an idler pulley for the bracket, when it comes in I'll probably finish the bracket and cut the points for the motor. Then the motor will be in and fabrication will be more or less done. Then I'll be on to wiring and finding a pulley and belt that fit. And hopefully that will be it!

I have had less time than I anticipated for this project. 4 people have moved in/out of my place in the past month and we're all still trying to get settled. Been having fun though. You'd laugh if you saw the amount of crap we've thrown out.

[ShadeTreeMech]

Good luck with finding the time to get it all together. I know how it can be hard to find time for pet projects. Hopefully things will calm down at your place soon!

[brucey]

Started mounting the motor today, and I realized I don't have a 1 inch drill bit.

I have a spade bit in that size, but not sure how comfortable I am cutting 1/4" aluminum with it. I'll test on some scrap and see how it does. If it works once (or twice, counting the scrap cut) It will still be cheaper than buying a 1" bit since an entire spade set is 7$ or so.

Also got my Kat's Block heater in the mail today, will try and mount that before the temperature starts dropping.

[Daox]

I'd suggest a good hole saw instead of a drill.