CarBEN EV5 Full Sized Prototype Construction - 5 Seat Electric Car From Scratch - Page 4 - Fuel Economy, Hypermiling, EcoModding News and Forum

Nevyn · 08-01-2012, 03:31 PM

This is superb! I haven't been on much, but I remember when you started designing it - gives me some motivation to work on my EV conversion for sure!

312 · 08-10-2012, 04:15 PM

Awesome!

NeilBlanchard · 08-11-2012, 12:06 AM

I'm back from a week off, so I'll get a little done. I've got a paying drafting job next week so there will be another brief pause...

NeilBlanchard · 08-13-2012, 11:32 PM

I glued another layer and then I had to cut another 8 sheets, so as to have all the parts for another 3 layers. If I cut 6 more sheets I can glue up another 6 layers. So, that would be another 18" of the car.

As I mentioned, I'm working this week, so pictures should be possible next week.

HyperMileQC · 08-14-2012, 12:36 AM

This is a fabulous thread! I love the fact that you are building a 100% DIY EV. Can't wait to see this thread evolve!

Great project!

NeilBlanchard · 08-20-2012, 10:07 PM

I've glued up another 6" and I've now got a nice random orbital palm sander, that makes a much smoother surface than before. I still need to do a lot more shaping inside the hood area before I glue any more layers to it. Here's pictures from today:

NeilBlanchard · 08-27-2012, 09:42 AM

I now have a 24" deep piece and a 20" deep piece -- they are held together with four 1/2" dowel rods for the moment. I have to nearly finish the shaping inside the motor bay while it is accessible from the back before I glue these together.

Here is the front 44" resting on the ground -- looking kinda' like the CarBEN EV5 Ranch?

Okay, now in the proper orientation:

As a reminder, here is the latest animated video of the SketchUp model:

NeilBlanchard · 08-27-2012, 08:33 PM

Question for those folks with experience shaping foam -- what works for smoothing small-ish concave surfaces?

JethroBodine · 08-27-2012, 10:49 PM

Looking good, Neil.

A guy at work said that he saw the tv show you were on.

NeilBlanchard · 09-02-2012, 11:26 PM

I added 4" to the second piece (photos to come), and I've now glued up another 6" (sections 11-13) for a total of 4'-6" of the front:

The gluing is slower now because the sections hang off my table too far (as you can see) -- I need to make a table the is ~6'x6' for the middle part of the car. All 4 battery bays have started -- the outer 2 extend just 2" forward, and the center 2 extend 6" forward.