David's Solectria Force Rebuild

[TheSGC]

Just a quick update, this morning I got the charger to run! My problem was with the control harness it came with, the section that was supposed to activate the main relay was busted so I just bypassed that and now I can freely reprogram the charger!

I think I found some temperature sensors that should work. This afternoon I am going to reprogram it for my 144 volt pack of NiMH and hopefully on Friday I can get it back into the EV and give it a charge.

[TheSGC]

I gotta get my camera out and take some photos.

I reprogrammed the NLG423 and set it for 145.2v nominal and pull no more than 12A from the mains. I got it into the Solectria and did a quick test run and it's looking good!

I'm now on vacation for the rest of the month so I have plenty of time to get this EV going. It's raining for the next few days so I will be setting up a tarp tomorrow and if I have any luck I will be able to test the drivetrain.

Once I am satisfied that all the electronics function I am going to bring it on down to the body shop and get it repaired. I think I will have the electronics all checked out and properly mounted in the next week, then I will prep the body and bring it on down for repair.

[TheSGC]

The Solectria runs!

Yesterday I was able to check all the connections and did a quick test run of the drive train. It all went well so I put the car on the ground and did a few runs up and down the drive way.

I did notice that the throttle has a broken spring and has not been maintained at all. Once the rain stops I'm going to test the potbox to make sure it is sound electrically, but the car does drive! There is a problem with the air conditioner but it's not necessary for getting the car on the road.

This week I am going to properly mount the charger, temperature sensors and ventilation fans and prep the body for repair. I'm going to take a few photos of the damage down to the body shop for a quote.

[TheSGC]

Yesterday I got a quote for over $3k to repair the body so my dad and I decided to do it ourselves. Either this week or next week I am going to hit up the junkyards to get the necessary parts and have at it.

I'm looking forward to repairing the Force, I've always wanted to try body work and since the car is now running I want it repaired so I can register it and get some miles on it. I'm not sure how long the body repair and full paint will take, but I'm not rushed for time.

Right now I am estimated 40 Ah or so available from the NiMH pack currently, cylcing should yeild better capacity over time. I'm hoping this pack will get me at least 20 miles, then it will be usable for my dad's commute.

[Daox]

What all needs to be done bodywork wise? Looks like you're missing a hatch and there is some rear bumper and quarter panel damage at least on one side. Anything else?

[TheSGC]

Originally Posted by Daox

What all needs to be done bodywork wise? Looks like you're missing a hatch and there is some rear bumper and quarter panel damage at least on one side. Anything else?

The front fenders are also pretty junky and the front right headlight needs replacing. I don't think the body work is too difficult, the challenge is finding the time to hit the junk yard to get all the parts.

[bennelson]

Thankfully a Force is just a Geo Metro.

You should be able to find replacement parts at junkyards if you just want a new fender or light for example.

The sheet metal on Metros is thin and easy to work with. Here's a video of me doing some body work on mine.

http://www.youtube.com/watch?v=CqGzjWFmYR8

All I did was remove the interior plastic panel, and then push out on the metal with my hand!

[TheSGC]

The Geo Metro is a simple car, which is why I think repairing it won't be too difficult.

I just need the weather to cooperate! There are thunderstorms for most of this week so I really can't get much done.

[TheSGC]

I haven't done too much on the Solectria due to weather and my new job. Last night I did continue removing stickers from the body and this week I want to get the body ready for the repair. I'm hoping to go get parts next weekend so we can get the body back into shape and work on the paint.

I do keep the batteries charged up and tomorrow I might drive it up and down the street to keep the brakes and drive train happy. I also have to get the batteries mounted better in the rear and get a fan ventilation running and the charger mounted properly.

[TheSGC]

Today my dad and I finally got time to hit up a junkyard. This morning we went to the local Pick N Pull junkyard and raided the only Geo Metro they had, a 1993.

We walked away with a trunk, tail light, rear bumper cover and hub caps.

I've also been spending nights here and there removing stickers form the body. Here is the Force with hub caps and the stickers removed from door and fenders:

Now here is the good stuff, the new rear lift gate (trunk) and new rear tail light. I also have a new bumper I need to put on, and I need to get rid of the plates at some point:

This is the gap that we need to repair before beginning the paint job:

The Force is now pretty water tight so the tarp is coming off it after several months! I am working on removing the adhesives from the roof and hood, then I plan on building some kind of paint booth and start the painting process. Once the paint job is done I am going to get the EV registered and on the road.