CarBEN EV5 Full Sized Prototype Construction - 5 Seat Electric Car From Scratch - Page 12 - Fuel Economy, Hypermiling, EcoModding News and Forum

freebeard · 10-21-2012, 03:27 AM

Makes sense I guess. Thin slices.

Carry on.

NeilBlanchard · 10-22-2012, 09:36 PM

I have finished cutting all the foam sheets for this project! The x-axis belt (on the CNC machine) has just about come to the end of it's usable life, but it hung on long enough to re-cut the last sheet. I got to show the cutting process to a friend, and needless to say, he was impressed.

And I only have 3 inches more to glue onto the main chassis! So, pictures of it sitting on it's "wheels" will be happening later this week. I'll be gluing the hatch door and the wheels skirts soon, as well.

Tango Charlie · 10-23-2012, 07:29 AM

Looks like we're getting an Indian summer this week. Hopefully it'll be warmer out your way, too.

NeilBlanchard · 10-23-2012, 09:15 AM

It is supposed to be mid-60's to the low 70's later on; and temps overnight should be mid-40's. I'll glue today if I have time.

Edit: I finished cutting the last sheet of foam yesterday, and I finished gluing the main chassis today! Woohoo!

Here are pictures - the last inch to be glued:

The rear bumper ready to be glued in place:

The Chassis with the pieces drying in place:

Later this week, I'll be able to take it off the platform and set it on its "wheels".

Edit: I'm bummed that Photobucket's new thumbnails are no longer links to the larger images...

Flakbadger · 10-23-2012, 02:23 PM

Hooray!

Christ · 10-24-2012, 12:25 AM

Neil, as an aside from this, why not chop up the excess and save the dust, put it in vacuum sealed bags and use it for floor insulation or ceiling insulation in the shop?

Christ · 10-24-2012, 12:26 AM

PS I can't believe I missed this project for this long... But I'm glad it was on the home page for me to see.

NeilBlanchard · 10-26-2012, 05:54 PM

Okay, I moved down into it's proper position, with the help of my son Nicolas!

Here you can see the battery bays in the floor; along with a space for a lateral link between the rear wheels:

The rear bumper is just 3'-6" wide. Here you can see the diffuser fins and the rear wheel strakes:

Now I can glue up the hatch door, finish the rear wheels, the wheel skirts. I made a litter frame (you can see it in the last photo) so two people can easily carry it. I've got to batten down the shelter before Sandy gets here...

HydroJim · 10-26-2012, 06:37 PM

How do you plan on making the doors? and will the windows roll down?

Weather Spotter · 10-26-2012, 06:49 PM