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

[deejaaa]

good luck with the rebuild and getting back on track. want to see it finished.

[Galane]

It's amazing what can be got away with as "additions" in some places VS the excrement one has to go through to build something all new.

Les Schwab Tires in Weiser knocked down their old main tire install building and "added on" to their old alignment shop (about the size of your garage and used for storing old tires and batteries since the newmulti-bay alignment shop was built). They only kept one block wall of the old building and the "addition" is about 5 times the size of the original.

[Xist]

I am glad that you have started picking up the pieces and salvaging all of your hard work. Good luck!

[DFBVT]

It’s good to see that you once again are starting to move forward with the CarBEN project Neil. Good luck with it and I'm looking forward to the day that you’ve moved beyond where you were before the collapse.

Cheers,

Dave Bowles

[NeilBlanchard]

It was a good day in the end - I got most of the repair gluing done. That is despite two extended rain showers, I managed to get the hatch door and the roof and sides of the chassis put back together. Only 6 small pieces remain to be glued in the floor. It is a bit scarred up, on the edges that collapsed, and where the wood framing hit.

Another big piece of the hatch:


Two pieces on the left side:


Three pieces on the right and center of the roof:


A couple more pieces on the hatch:


Last big piece in the roof:


The six pieces yet to go in the floor (plus some small bits of the hatch that got glued in, and one piece of scrap):


Several shots of everything on the top back together and drying:


The worst scar on the hatch is on the edge of what will be a window, so that will be fine. The other missing shards will have to be filled in with some spray foam.

It is almost back to where it was in early winter...

[HydroJim]

You might have to change the name of the car to the Pheonix. Your dedication to getting this thing rebuilt is commendable. I can't wait to finally see the finished product.

[Galane]

Originally Posted by HydroJim

You might have to change the name of the car to the Pheonix. Your dedication to getting this thing rebuilt is commendable. I can't wait to finally see the finished product.

The Phoam Phoenix.

[jray3]

Originally Posted by Galane

The Phoam Phoenix.

CARBENstein! (complete with stitch marks and a couple of little bolts sticking out until the final paint job)

Keep up the fight, Neil- it's been quite inspirational!

[NeilBlanchard]

I have a small update - I had hoped to do more; but I ordered 25 yards of 38" wide 8.9oz S-glass from US Composites last week and it arrived Thursday. I used a can of low expansion (urethane?) foam on most of the gaps and cracks (some from the damage and some that didn't glue well) and that's where it sits, now.



I trimmed off the excess with a hacksaw blade, and it looks to be very sturdy foam. I will rasp and then sand it down. I'm thinking I will fit the windshield and the wipers, and then start to 'glass the roof and the hatch door.

[freebeard]

Are you going with wood glue or polyester resin?