Ben Nelson's Electro-Metro Build thread

[MPaulHolmes]

I heard bearings are changed VERY infrequently, like every 100,000 miles of EV driving. Also, Jim Husted, the EVDL's motor expert told me that to smooth out the copper bars, they have a 'commutator stone'. I don't know if it's bad to use a lathe or not, but there's got to be a reason commutator stones exist.

[bennelson]

Been so busy with so many things lately, but tonight I ACTUALLY MADE PROGRESS!!!

I put the motor back together and went over to Hot Rod Jim's to check the shaft length against what we would need to figure spacers to put the whole thing together.

We put the motor on end (on blocks, because it's double-shafted) and set the transmission on top of it.


With both shafts touching, there is about an inch gap between the adapter plate and the motor.


After talking it over, we decided the best way to go would be to trim the useless little pointy tip on the tranny shaft, and about a half inch off the motor shaft.



Then, we can make another copy of the adapter plate and put them both together double-thick. That way, it will be a solid plate, using no spacers. That should look nicer, be very solid, and most importantly, keep the whole thing short! This mounts crosswise in the Metro engine compartment, which isn't that big!!!

I also talked with Jim about what solvent is the best to use to clean up the motor and transmission. After seeing how nice Jim's adapter plate is, it would be a shame to go on a dirty transmission and motor!

A good while back, I was thinking about painting the motor. Then I saw the Project Forkenswift with the new paint job for that EV show a while back - fantastic!

I was even originally thinking green for the EV parts (curse you Darin! stealing all my ideas...) I already have a can of yellow Rustoleum for from the cycle's paint job. So folks, what do you think, yellow, green, or other for the motor paint job?

See all the photos of tonight's activities at:.Mac Web Gallery

While you are there, check out the photo of Jim's mailbox.

PS: I had to teardown the motor again for Jim to work on the driveshaft (takes about 3 minutes to do!) Since it was open anyways, he took a look at the bearings and said they looked like they were in great condition.

I am hoping that tommorow, I will get some time to clean up the motor and tranny - both are still really ugly and greasy!!!

PPS: Look for a video update tomorrow!

PPPS: That's Jim in the photos. You know what I look like. I'm the crazy one with the beard and the glasses.

[MPaulHolmes]

I vote for periwinkle. It's sort of a soft light purple color. It's also those little creatures that stick to rocks in rivers, sort of like how we don't want your motor to "fall off" the rock (your car) while you're driving.

[bennelson]

Video Updates now include fancy graphics!

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

Doh! I am so bad with numbers and dates. Please ignore the 8-21-08 graphic. It should be 7-21-08!!!


NEW PART 2 VIDEO!

http://www.youtube.com/watch?v=GQuXoD8nPoM

[bennelson]

I degunked the motor and transmission.



The motor is going to be yellow. It's what I had. (Leftover from the motorcycle gas tank.




I also scrubbed the transmission down as best I could using mineral spirits to clean it up.



Starting to look like I have some actual electric vehicle parts around here!

[Daox]

Good updates!

[bennelson]

THE MOTOR IS IN!!!

Ok, not really, but I did get to do a "test-fit".


Today I put the motor back together, sans driveshaft (which is still with the machinist.)

I degreased the inside of the whole thing as best I could. There is actual cast iron under all that petro-slime! I think there must have been a leak in the original forklift's differential and it just continuously oozed onto the motor.

I completely removed all the brush-holders and the field coils, cleaned them, and reinstalled them.



After getting it back together, I put the transmision back it the car, (held in by two bolts) just to see it and check placement.



Then, I tried hurting my back, by lowering the motor down onto a crate on the ground so that the motor would be roughly where it should go in the engine compartment.



It fits! (Barely!)
And that's WITHOUT the driveshaft in it. There is about an inch or so between the farthest bit of cast iron on the commutator end and the side of the engine, er, motor compartment.

Looks like I will have to take off the tailshaft - no idea how it will fit otherwise!

The mounting holes on the commutator end are in much farther, and should be perfect for supporting the butt end of the motor.


Here you can see the crate that I set the motor on for rough placement.



I also used the "Heat & Beat" method of removing one of the back wheels. My wheels look like crap! I saw a little video on YouTube about refinishing wheels, and it looked easy, so I gave it a try!



I think that's going to be it for a few days. I have to work the rest of the week and help my sister move on Saturday. Maybe I can do some more work on this project on Sunday...

-Ben

PS: see more photos at: http://gallery.me.com/benhdvideoguy#100161

[bennelson]

I am not addicted, I can stop posting any time I want!
(Where's the smiley for denile?)

Anywho, the paint on the wheel dried.





What do you think? Too Mickey Mouse? Makes it look like a trailer tire, doesn't it. Look at the front wheel for what the white tire looked like before.

Paint. It's cheaper than hubcaps.

[dremd]

i vote metallic charcoal or maybe silver for the wheels.

[MetroMPG]

I still think you should leave the tailshaft on, and just drill a hole in the "frame rail" where it will go. Yellow motor looks great in that black engine bay.