Ben Nelson's Electro-Metro Build thread

[bennelson]

All jokes aside, the emissions people are NOT going to fall for any sort of FAKE test.

I have talked to a couple of EV buddies, but none of them actually has a current, registered, EV CONVERSION.

Guy A has a ZENN, that's NEV class - exempt from testing
Guy B has a Citicar - that's grandfathered in as just a car, and too old for testing.
Guy C hasn't finished his conversion yet.
Guy D hasn't started his conversion yet.
Guy E has an S10 conversion he is driving right now, but his old registration isn't up yet, so it's still on the road under the last ICE emissions testing. He is planning on using me as a guinea pig to find out what he will have to do!!!

Looks like I get to be the sucker to muck through the system to see what needs to get done!!!

[bennelson]

If you are in the States, and have a pretty quick internet connection, please click the video to go directly to YouTube, and select the WATCH IN HD option!

This is my first Electro-Metro YouTube video in High-Definition!

http://www.youtube.com/watch?v=sZS3bbEPshY

[MetroMPG]

Whoa- high definition Electro-Metro update. I could see the frozen boogers in your nose!

[kimer6]

Awesome...First Class!
Now you need battery powered socks to drive it!

[bennelson]

Originally Posted by kimer6

Awesome...First Class!
Now you need battery powered socks to drive it!

FINALLY! Somebody comes up with a good electric heating idea!!!!

At least I had enough Metro clutch plates to work from!

[Christ]

Whoa.. that E-motor sounds quite aggro in there LOL.. Seriously, when you revved it up the last time, I wasn't sure it was just a regular e-motor.

[bennelson]

The camera microphone was set to automatic volume control and I was wearing a wireless mic.

The motor noise actually seems louder in the car than outside it. I came through very clearly on my mic.

[Intrigued]

Originally Posted by bennelson

The motor noise actually seems louder in the car than outside it. It came through very clearly on my mic.

Now we need a tutorial on how to rubber mount an e-motor to a car...

I've started a little research on titling and licensing a converted EV here in Missouri. The closest thing I could find on the online "gub'mint speak" site was what they called a "reconstructed vehicle," which may need to be taken to an official Highway Patrol inspection station - not the state inspection place, but the ones that are spread out one per "Troop." I'm waiting on official word from both them and my insurance carrier at present.

...it's a good thing I have a car dolly, and a hitch on my Intrigue, because the closest HP Insp. Sta. is like 60 miles away, and I've already contacted a couple of Craigslist possibilities on a donor!!!
e-...

[rocky2009]

Hi Ben, I was thinking that the reason the spline teeth were so worn and eaten away is because the transmission shaft is hardened, extremely tough, and the clutch spline was once hardened, and heat treated, but when you welded it, it lost its hardness, so the problem will probably return. I was wondering if you could take it somewhere to have it heat treated.

Thanks for the kool videos
Greg

By the way, keep up with the electric spirit. The evil oil monsters lowered the price of gas to get us once again addicted to oil and to forget electric. They only care about the economy, not the air we breathe.

[bennelson]

Hey Rocky2009,

Welcome to Ecomodder!

If hardening is an issue and it fails again, I'll just have to make a new one!

I really think the problem with first coupler was more of an alignment issue. The Motor side splines were perfect, and were also welded in the exact same way as the transmission side.


MILWAUKEE HYBRID GROUP MEETING:
This morning was a Hybrid Group Meeting. I hitched up the Metro to the S10 and drove to the Oak Creek Public Library.

Can you find the NON-Hybrid Car in this photo?


Here's a hint, from another angle.



When I first got there, the parking lot was nearly empty and had a slushy, snowy covering.

So I just had to do something I never had done before: ELECTRIC DONUTS.

I put the car in first gear and just slammed on the accelerator. I could spin the car 360 from a dead stop - instantly. WAY TOO MUCH FUN!

Once people started getting there, I showed off the car a bit, with the hood and trunk open to show off all the exciting EV parts. Several people were impressed with the low cost of the project. I got lots of "Good Job!"s

After the meeting, one guy in particular was really interested in the project. He said he wanted to do a Metro electric conversion too. I think he will show up to the EV build day tomorrow.

Justin, one of the drivers in the recent 48-State record run, took my car for a ride around the parking lot. It didn't take him long go get the idea of clutchless shifting. Seemed he liked the electric. He did comment on really being able to feel the acceleration in 3rd gear.

After that, I towed the car off to Tom G's, as he isn't that far away, and I dropped off the car with him for the night.

Right now, the 'Lectro is sleeping peacefully in Tom's heated garage, just waiting for some more work tomorrow.

The main thing I want to do is adjust the Potentiometer. When I measured it with my multimeter, the max read with the pedal to the floor was 3500. Properly calibrated, it should be closer to 5000.

Just imagine the electric donuts I could do with full throttle!!!