CarBEN EV5 Full Sized Prototype Construction - 5 Seat Electric Car From Scratch

[freebeard]

And I have a new tool - an oscillating saw, which is also a small triangular sander.

Nice tool. Didn't we talk about that upthread? That's rhetorical, if I cared I could go look.

[NeilBlanchard]

Yep, I just bought it yesterday. It has about 10 different types of blades and a sanding attachment with an assortment of sandpaper, too.


(click on image for info)

Porter Cable Oscillating Saw Review | Tools In Action - Tools and Gear for the Working Man

The kit was $120 at Lowes.

[bennelson]

Looking great!

Keep up the good work!!!

[Flakbadger]

This looks fantastic, I have been watching for a long time. I'm sure you already covered the reason(s) for the unconventional door setup, but I must have missed it. Why? Is it for ease-of-manufacturing and structural rigidity, and overall reduction in cost and complexity? I know it would be a lot easier to get in and out of at a car park, that much is certain.

Anyway it's looking great, and I appreciate your video. Keep up the awesome work and I look forward to seeing more progress!

~Matt

[Afrersize]

I know this may be a little off topic, though will this car have regenerative braking? Also does the electro?

[freebeard]

Afrersize -- He's designing from the outside in and expecting drivetrain tech to have advanced by the time he has a viable shell.

[NeilBlanchard]

It will be an all electric drivetrain with a large lithium pack. It was design around 768 EiG cells that would total about 55kWh. The battery is going into the floor. And yes it will have regenerative braking. Edit: yes, I'm waiting until the end to settle on the battery, etc. hoping that it will either be less expensive and/or lighter weight.

The single entry door is for simplicity - I'd have to have that door anyway. It also makes the car much stronger and lighter weight, since side doors and the door opening each have to be strong and rigid to hold up in a side impact. The large hatch door will act as a roof when it is open; keeping out some precipitation at least.

If it works, then great, but if it doesn't, then I'll either add a side door on the right, or just build the next one differently. The edges of the opening will be like handrails and I've been getting in and out of it quite a bit lately. The hatch itself will be remotely latched closed so that you have the headroom until you sit down.

[Christ]

In the next design, if the roof door doesn't work out, it might work to have a rear or side door that slides up instead of opening out? Probably on the aisle side, so that you can load groceries etc in that space easily as well and leave enough room to get in and go to the front.

[NeilBlanchard]

It got up into the mid 40's today so I got a fair bit of time in working on the rabbet joint on the hatch door. The door fits into the opening, and I scribed it and then cut one pas, then scribed it again and cut and sanded a second pass. It now needs some fine tuning to get it sitting evenly, and then another scribe line - and then it can be shaped to be completely flush with the roof.

Here are photos in chronological order:

[Christ]

Looking at the pics doesn't do justice to how much work you've put into this... It's really coming together nicely.