The Firebrid Hybrid Convertible Project (Prius platform swap)

[Bill the Engineer]

All of the machined and water-jet cut parts from this most recent lot cost me US$370.00 all together, although some of the other shops quoted much higher.

Bill the Engineer

[Bill the Engineer]

Got the new steering column mounting brackets installed to test the fit.





I was going to do more, but then the skies opened up and I had to hurry up to cover the car again because of the occasional roof leak in the garage. Sigh.



Bill the Engineer

[Bill the Engineer]

Electrician's gloves arrived. Traction battery removal this weekend so I don't need to flip-out over every rain storm. Not willing to gamble with any residual charge that might still be in the battery.

Also sent two bumper bracket plates to a friend with a hydraulic bending press to get that pesky last bend made. I'm hoping I get them back by the weekend.

Bill the Engineer

[trseven]

The Prius Pack has relays inside the case so there should not be any voltage at the points that the cables connect. When the car goes "ready" you can hear these pick. Plus, there is an interlock that you can pull that disconnects the pack in the center making sure that there is no voltage at the output connections. Its pretty safe with the interlock pulled but the gloves are a good idea. I've rebuilt a number of packs in the past, I've got electricians gloves but never used them! I'm not sure on the Prius V but the Gen II uses a spot on the interlock to release the cover over the main cable connections. Good Luck! Cool build!

Gerry

[RedDevil]

On my Insight pack I saw residual voltage on the terminals for some time after switch off.
The battery cells are cut off all right but the control electronics have capacitors etc. that hold some charge.
Always test the contacts with a volt meter before you do anything on a full pack.

Also, though the main contacts are cut off some parts deeper in the Insight pack do hold the full voltage. That may be so with the Prius pack too? When the pack is open make sure nothing drops inside.

When I was assembling my additional booster batteries I wrapped a plastic strip over each cell terminal connection, feeling silly about it but just in case.
Almost done, I let a wrench slip and it dropped right on top of my cell array.
Nothing happened because of the strips.

I could not imagine the mere possibility of losing control over the wrench while assembling the battery, being concentrated and well prepared on the build and all, but it happened nonetheless.
When I thought about covering the terminals I told myself that now I had to do it.
I would regret it if I thought about it, skipped it and had an accident because of it.
You'll never regret extra safety measures. You will regret being short on them.

[Bill the Engineer]

"Special Statement
Issued: 6:01 AM EDT Aug. 27, 2016 – National Weather Service

... Very warm and humid conditions to continue today...

High temperatures in the lower and middle 90s will combine with
high humidities to produce heat indices near 100 degrees this
afternoon.

If possible... spend more time in air conditioned or well
ventilated places this afternoon. If you will be outside... wear
light weight and loose fitting clothing and drink plenty of water."

... well dang... no welding today...

I'll do what I can...

Bill the Engineer

[Bill the Engineer]

Got an early start trying to beat the heat...

Now that I have the electrician's gloves, I got into the Traction Battery, disconnected the main drive cable, and removed the battery from the car. The hardest part was getting the orange safety cap to come loose. The battery assembly is also surprisingly heavy.





I then took a few minutes to trim back the edges of the Gen II Gas Door assembly I will be using in the near future.



Last for the day, I test fit the brake pedal parts and determined that a hole in the Firebird firewall needed to be made larger for the Brake Pedal Connector Bar to pass through.



Once that was cut out, I test mounted the brake pedal components for a fit check.



By that time it was getting into the heat of the afternoon so I had to stop.

I'm looking forward to the 3-day weekend next week!

Bill the Engineer

[Daox]

Not bad progress for a mornings work Bill. Keep it up, and thanks for the updates!

[Bill the Engineer]

Welding has begun!





Bill the Engineer

[Bill the Engineer]

Brace yourselves...

Sunday was one of those days that you dream about. It was the middle day of the 3-day Labor Day weekend, there weren't any home chores to do and the weather was perfect. The day started with finishing the welding and grinding on the front bumper adapter brackets.




Then I mounted the brackets onto the Prius V Chassis in place of the cardboard mock-ups that had been there. These brackets simulate the ends of the former frame on the original Firebird chassis.




Then I mounted the Firebird radiator support to the brackets. (It is the part that holds the front of the fenders in place, and where the hood latch parts are mounted.)




Next I mounted the original Firebird front bumper brackets to the new adapter brackets.




And finally, I mounted the Firebird front bumper assembly onto the Prius v chassis.




It was an EXCELLENT DAY!!!

Bill the Engineer