Ben Nelson's Electro-Metro Build thread

[bennelson]

Well, a couple of things here.

I don't have a flywheel anymore, so anything that bolts to that is out of the question.

I don't think there is anything wrong with the lovejoy, it's just that I am under a limited length. I think if I had a lovejoy half on the motor shaft which connected with a key instead of splines, I could get the coupler farther up the shaft.

Hopefully, the shaft can be trimmed a bit more, and that will take care of the length issue.

[johnmyster]

Well, that flywheel issue needn't be an issue to other users. The one we had just had six bolts in a circle. If someone put a flange on their motor shaft, they'd be set.

Sounds like you're on the right track. I just know you're well researched in all ways ev-conversion oriented, and was wondering if other people were using other products.

I still think you should use my brake-activated brake-assist brainstorm nugget. It'd be the hottest thing under the sun.

[bennelson]

Seems like the next step up from a direct coupler of some sort (such as a lovejoy) is to use the original clutch and flywheel, or at least a trimmed down version of the flywheel.

If I kept the flywheel, I would keep the clutch as well. Seems like more weight and design needed than necessary for a basic conversion.



I started taking the dashboard apart. I wanted to get at the back of the cigarette lighter plug. On this car, it is switched. I thought I could use this key-switched power source to turn on power to the DC motor controller.

When I took out the center console trim to get at it, guess what I found!?




The Airbag Computer! Nice to know it is totally separate from all of the internal combustion engine stuff. I will just not poke it while working around the dash here.

I also just discovered that once I pay for the 72V controller, I will have about $90 still left for this project. That's enough to buy a nice, on sale car radio with CD and MP3 input. That way I can rig up an MP3 player to play electric car sound effects, The Electric Slide song, or a recording of me talking about the car, so I can save my voice at car shows.

[johnmyster]

Yup. SIR systems are stand-alone. Stay away from the yellow bundles of wires and you'll keep her intact.

You pulled out the engine, fuel tank, etc., and you didn't free up any additional ignition circuits? This way, if your cell phone charger malfunctions and pops a fuse, you'd be dead in the water. Worst case, there should only be three or four fat wires in the steering column. I'd start with the yellow one.

I'll make you a CD with tracks of my motor revving. That way you won't miss it.

[bbjsw10]

Originally Posted by johnmyster

additional ignition circuits? in the steering column.

Car Alarm, Car Stereo, Mobile Video, and Cruise Control Info for Installers
That should get you the right wires.

[bennelson]

Wow, thanks for the radio installation link. Looks like a flood of information. I will have to spend a few hours digging through that sometime.

I did test out the cigarette plug. Plenty of power going through there.

I went to test it again, and got nothing. Must have blown a fuse, right? The Metro has the worst fuse box ever! It's WAY up under the dash and nothing is labeled!

Once I figured which one it was and replaced it, I could get power through that connection again.

I have a 12V relay which I want to turn on another switch when it gets power to it.

The idea is that I turn the key, it activates a relay, and that connects power to the Controller. Thus, the key turns the controller on and off.

I tried it out, using a lightbulb, and volt meter to test the switched signal out of the relay. I couldn't get anything. The relay clicks on and off, but there is no voltage out the other two connections of the relay.

Do I just have a bad relay? Am I doing something wrong?


I also called the machinist and made an appointment to go see him Thursday evening.



Strangely, pulling the engine really doesn't give you any spare 12V wires. The main one that goes to the thingy that does to spark plugs goes through some sort of resistor. Even though it reads as 12V, it's not enough to power a relay.

Now the starter wire may have some interesting possibilties.....

[bbjsw10]

Originally Posted by bennelson

Wow, thanks for the radio installation link. Looks like a flood of information. I will have to spend a few hours digging through that sometime.

I have a 12V relay which I want to turn on another switch when it gets power to it.

No problem here is another one. Diagrams

And your relay should be as follows:
85-ground
86-ignition
30-fused battery
87-switch
87a-empty
This way the relay will jump battery power to the switch when key is turned on.

[bennelson]

Originally Posted by bbjsw10

What about going to a junk yard and getting a convertible air pump...

What is special about the air pump in a convertable? Is this used to somehow raise and lower the convertable top?

[bennelson]

I just got an e-mail from Tom G.

He had promised me a vacuum canister he had laying around. Well, the just told me that he found it, WITH a 12V vacuum pump attached!!!

Next time I see him, I will get it and hook it up!


I also just got my shipment in from China, er, Ebay.



In the picture is a volt meter, an ammeter, and shunt.

The voltmeter goes up to 500v and the Ammeter up to 500 amps. The shunt looks a little wimpy for 500 amps. Since the motor is out, I don't really have any way to test that.



Hey, look at this!



All the wheels are the same color! I also have two of those little "Geo Hubs". Only two came with the car, so I put them both on the same side. At least one side looks nice that way!



Anybody know where I can get two more of these?

[bbjsw10]

Congrats on tank and pump that is awesome.

I watched "Who killed the electric car" tonight because of this thread. Got the dvd at library if anyone wants to watch it, check there it is free that way.

This thread has me thinking I could do this too. Now the questions.
1. How did you go about finding the forklift, I don't know where to start.
2. Is there anything that could be used for heat, Ohio gets cold and want a year-round EV.
3. What do you think about a VW bus? I saw one sitting the other day and that HHmmm that would be cool. Solve there high center of gravity with a bunch of low slung batteries.

I am going to have to start at the start of this and read post by post when time allows. I figure save my Xfi for longer trips which is next to never. Build a seperate EV. Or sell Xfi to fund a nice EV and when long trips are needed just use my Wife's Civic, or a rental car. Figure it would be cheaper if needed to just rent one from time to time. I hardly ever drive more than 50 miles from home. Maybe twice a year, what do you guys think?