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

[JB3]

Damn!
What a setback, sorry that happened.

No where near the same level of work compared to what you've done here, but this reminds me of the time I was moving an engine with a custom just completed aluminum oil pan and the hydraulic hoist failed and smashed the pan to kingdom come and also destroyed the oil pickup.

All I can say is sit back, take a break from the project, and reassess after the shock is past. You might find that the repair of the damage leads you to some exciting ingenuity that was better than before.

[NeilBlanchard]

I'm planning to clean out my 1-car garage an to move the CarBEN chassis inside this Saturday. I would appreciate it if anyone could lend a hand. PM me if you want to come and need my address.

I won't be able to glue anything back together until it gets warm. But I think it will be repairable. The one piece that I have not spotted yet is a small (but important) one from the floor; where the ridge punched through. This is essentially supporting the rest of the frame that is left (sorta') standing.

[aerohead]

Neil,I'll be there in spirit.
I've had losses,but nothing of the magnitude your facing.
I want to think that the foam will have a 'memory' and maintain its original form such that it can be jigsawed back into place when weather permits.
I framed in a very rude,dirt floored 'shack,' with corrugated metal roof after an ice storm collapsed my metal tubing and tarp enclosure years ago.
As an outsider,and with no skin in the game,I'd say that the 'Carben' is among very few projects worthy of all the sweat and agony it's going to take to bring it to conclusion.I've developed an attachment to the project over its evolution,and even if it were never finished,would just the same,have benefited from your concept and dogged determination to bring it to fruition.
My mom was fond of saying that "time helps heal all wounds."
Thanks for all you've done,and willingness to 'think about' slugging it out.

[NeilBlanchard]

I cleaned things up today - totally dismantled the shelter, and cleared out enough of the garage to get the chassis inside (just!). I had a friend's help and it made a big difference. (My strapping 6'-5"+ 16yo son on the other hand only managed to help stow 9 tires(!) in the basement.)

http://www.youtube.com/watch?v=J_GCP...zmMEZaHg_-BttA

It was a near perfect day to do this - ~53F and partly sunny. Lotsa' melting goin' on! We are due to get rain, so I was not going to let CarBEN sit out in that - the shelter was a giant funnel right down into the inside ...

[freebeard]

"That'll buff right out."

[aerohead]

Neil,glad she' out of harm's way.I predict a better nights sleep.
I got interested in one of Chrysler's Ghia-built dream cars of the mid-1950s only to learn that she went down with the Andrea Dora and has been resting peacefully at the bottom of the Atlantic.
Progress sure has its price.

[HydroJim]

Glue her back together, fill in the seams, and start sanding! She'll be fine!

[NeilBlanchard]

I had a long talk with a friend yesterday who has about 12 Saab 900's as parts cars and he knows a lot about the front suspension and the drive shafts, and I know where I will be buying my front suspension. He also has a lot of ideas about the rear suspension - I may be able to use a Honda / Acura multi-link suspension. Which would be great for passive "steering" that improves the handling. I'll be visiting his shop (up in New Hampshire) fairly soon to get a first hand look at all the parts.

The front track of a Saab 900 is listed as 55.9" and the front track of CarBEN is ~51.5" so roughly 4 1/2" narrower. And the width of the BRUSA SSM1-6.17.12 motor is 250mm (9.85") with the 6.4:1 reduction and differential which is 235mm (9.25") is probably much wider than the final drive of the Saab 900, so the length of the drive shafts will have to be shortened.

If the tall and narrow Bridgestone tires become available, then that might change the equation of the width somewhat.

Also, does anyone have experience with transferring a VIN from a old car to a newly built one?

[TheSGC]

Originally Posted by NeilBlanchard

I had a long talk with a friend yesterday who has about 12 Saab 900's as parts cars and he knows a lot about the front suspension and the drive shafts, and I know where I will be buying my front suspension. He also has a lot of ideas about the rear suspension - I may be able to use a Honda / Acura multi-link suspension. Which would be great for passive "steering" that improves the handling. I'll be visiting his shop (up in New Hampshire) fairly soon to get a first hand look at all the parts.

The front track of a Saab 900 is listed as 55.9" and the front track of CarBEN is ~51.5" so roughly 4 1/2" narrower. And the width of the BRUSA SSM1-6.17.12 motor is 250mm (9.85") with the 6.4:1 reduction and differential which is 235mm (9.25") is probably much wider than the final drive of the Saab 900, so the length of the drive shafts will have to be shortened.

If the tall and narrow Bridgestone tires become available, then that might change the equation of the width somewhat.

Also, does anyone have experience with transferring a VIN from a old car to a newly built one?

You can't transfer a VIN in MA, they are set in stone by the car manufacturer and the VIN number relates to model, engine, safety features, etc. If you want CarBEN registered you have to set it up as a kit car and you will go through the kit car inspection process and they will give you a VIN-like number when its complete.

[Galane]

Custom Built Car Registration in Massachusetts Massachusetts RMV Registration for Custom Built, Kit Cars, & More at DMV.org: The DMV Made Simple