The Firebrid Hybrid Convertible Project (Prius platform swap)

[Bill the Engineer]

New electrical service installed today for the air compressor and MIG welder, plus new 30amp 120V lines for other power tools. Now things can get rolling on the project!



Bill the Engineer

[Bill the Engineer]

Had some fun for a while today in the garage on the project. Since the body is now lower on the chassis, more modifications were needed to fit the right fender to the body.



Fortunately there is still good clearance over the top of the strut towers.



Holding the front bumper up to the car showed me that the fender and hood stretch is still necessary. I will also need to rework the hood hinges....




..but then the sky darkened and it began teaming hard enough to splash into the garage.



Hoping that the evening is better and I can get out there again.

Bill the Engineer

[me and my metro]

Looks great!

[Bill the Engineer]

One of my Facebook buddies pointed out to me that I just increased the value of my house, since the 240v outlets can also be used to charge an EV or PHEV in the future.

Cool.

Bill the Engineer

[Bill the Engineer]

Design of the adapter brackets to mount the Firebird front bumper on the Prius v chassis is coming along nicely.



Next step will be detailed part drawings so I can get them quoted by a fab shop. Some of the bends are too hefty for my equipment.

Bill the Engineer

[Doc Joe]

Originally Posted by Bill the Engineer

Design of the adapter brackets to mount the Firebird front bumper on the Prius v chassis is coming along nicely.



Next step will be detailed part drawings so I can get them quoted by a fab shop. Some of the bends are too hefty for my equipment.

Bill the Engineer

Hello Bill,

Please do not take this wrong, but when I look at your design you have square corners. Being in the aircraft for over 25 years, we never have square corners and always have a small radius. Please add these to your design to prevent stress cracks later. If you were not done with your design, please forgive me. Love the project and what you are doing. Keep up the great work.
Doc.

[Bill the Engineer]

Originally Posted by Doc Joe

Hello Bill,

Please do not take this wrong, but when I look at your design you have square corners. Being in the aircraft for over 25 years, we never have square corners and always have a small radius. Please add these to your design to prevent stress cracks later. If you were not done with your design, please forgive me. Love the project and what you are doing. Keep up the great work.
Doc.

Not a worry, this is just the early stage layout. Filleting and chamfering is yet to be added. I am keenly aware of stress raisers, bend radii, and good design practice for welded parts. I will also add tab-and-slot features to keep the parts in position during welding, as well as increase the strength of the weldments. The welds will be ground smooth once completed to eliminate discontinuities too. I'm just glad that I could keep each bracket to just three welded components.

Bill the Engineer

[Doc Joe]

Originally Posted by Bill the Engineer

Not a worry, this is just the early stage layout. Filleting and chamfering is yet to be added. I am keenly aware of stress raisers, bend radii, and good design practice for welded parts. I will also add tab-and-slot features to keep the parts in position during welding, as well as increase the strength of the weldments. The welds will be ground smooth once completed to eliminate discontinuities too. I'm just glad that I could keep each bracket to just three welded components.

Bill the Engineer

Very cool and thanks for not getting bent out of shape on the comment and suggestion. I love what you are doing and enjoying this 100%. So next year you need to drive this on the Power Tour, which is happening now here in the Midwest and shock all the Hot Rodders. I think it would be so funny to see there faces when they find out it is a Combo meal... BAHAHAHAHA

2016 Power Tour - Hot Rod Network

I live in Wichita KS and they are stopping here on Thursday night and I so plan to go have a look at all the cars. So wish you would have had this project done and in the show. Till next time...

Doc.

[Bill the Engineer]

Bracket layout completed and detailed part drawings underway.





Bill the Engineer

[Bill the Engineer]

I am really enjoying making the drawings!



Bill the Engineer