Electric Assist Project: E-charger (2000 Subaru Outback) - Page 15 - Fuel Economy, Hypermiling, EcoModding News and Forum

Phantom · 10-01-2010, 01:24 PM

Going by what dcb said get a friend to help by having them sit in the car start it up and with the parking brake on add load to the engine, as they are doing this see it the motor and engine move the same amount in the same direction.

Other wise get the largest washer you can and place it at the end of the pulley so it cannot move off the idler.

brucey · 10-01-2010, 03:10 PM

Yes, the idler is smooth. It seems aligned about the best I can do. The charger is off maybe 1 degree on the angle of the shaft, since the pulleys on the front of the car face slightly upwards.

Here is some more pictures for more ideas, but for right now I'm going to try the giant washer idea and have a friend start the car for me. PS: The last picture has the belt on, but it wasn't tightened.

Frank Lee · 10-01-2010, 04:38 PM

Not a fan of the washer idea. It wouldn't seem like a thing that addresses the root problem(s).

ShadeTreeMech · 10-02-2010, 07:30 AM

Quote:

Originally Posted by Frank Lee

Not a fan of the washer idea. It wouldn't seem like a thing that addresses the root problem(s).

Frank's logic is right on the money. A smooth idler perfectly lined up will not walk the belt.

Have you ever had to adjust the belt on a belt sander? Insanely small adjustments make a huge difference, and I think this is how you have to think. It is possible that a .005 inch shim in the right spot will make it work perfectly.

My suggestion is to find the happy spot by adjusting the e-charger at idle. Loosen up the mounting bolts bolts on the charger, and with the engine idling, AND TAKING CARE TO STAY AWAY FROM THE BELT (emphasis added on purpose!!!!!!!!!!!!!) move the charger motor around from the opposite end of where the pulley is while watching what the belt does in response to the movement. This will likely require a lot of patience, several restarts to adjust how tight/ loose the belt or mounting bolts are, and preferably an assistant to play with the gas pedal to test various adjustments on the fly. Having some metal shims of various thicknesses on hand will be very useful. And to save the belt, I'd tighten the idler just enough to make things move, but loose enough it can fall off harmlessly.

I'm betting there is a ever so slight missalignment, or possibly the mounting plate is flexing slightly causing a temporary misalignment. By shimming the e charger in the right spot you should be able to solve it.

Just don't give up! Once you figure it out you'll be glad you did, and you'll be able to pat yourself on the back for the sucessful installation of the Brucey E-Charger©!

brucey · 10-02-2010, 04:22 PM

So today I learned that belt 5050650 (65.0") does in fact fit, but I need to remove the alternator from its bracket to get enough slip to let it on. With it on though, it is much tighter than the 65.3 (for obvious reasons) and I think I will end up using that belt when I get the walking issue solved. It's much easier to find.

That said, even with the shorter belt, the walking continues. I see no flex when it starts, it just wants to walk around the idler and that throws it off the PS pulley.

I'll try and get a video up this weekend for everyone to look at.

brucey · 10-02-2010, 07:57 PM

Think I might have found the problem, I know it's a lame picture but this is the best I could do, it's a bit crowded:

The idler is about 1 degree off from the power steering pulley.

I can't tell if the E-charger is too, but scrutinizing everything about the system, this is the biggest problem I can find as far as misalignment.

In good news at least, I FINALLY got the block heater installed.

Gonna re-inforce my front skid plate a bit then get it all back together, hopefully I won't have to take it off to do any E-charger related stuff.

ShadeTreeMech · 10-03-2010, 04:27 AM

Keep up the hard work mate, you'll get her going soon enough and we'll all want to throw you a party for your dedication to an idea some have said was a crackpot idea.

HaiRuiDe · 10-03-2010, 05:25 PM

Lock it down so we all can do it too!!! I wanna hybrid a 2000 Saturn Wagon!!!

brucey · 10-04-2010, 06:28 PM

So I got the whole bracket off today and gave it another washer and about 1 degree more of angle. This makes the e-motor look a bit off now, so I might end up having to do the same with it. Pulley puller time!

I also don't have time to test it tonight, seeing as my basement is currently flooding and my water pump doesen't want to start.

Daox · 10-05-2010, 07:18 AM

I figure you probably know, but that is supposed to be installed vertically, not horizontally. Its possible you could burn out the heater with it running like that due to not enough flow through the heater. Although I know Darin has his somewhat horizontal too.