Mazda MX-6 build thread (EV conversion)

[Astro]

Originally Posted by thingstodo

Wow - you seem to have a strong handle on what everything weighs and what battery capacity you need.

I have posted up some weight measurements in my build thread.

They are very similar to your own, actually really similar if you added in the weight of the fluids (coolant, petrol, oil) that may never go back in the vehicle.

I found myself staring, mesmerised by the amount of nasty, oily, dirty, stuff that was removed. With all this oily stuff gone, the dust and dirt that sticks to everything and gets baked on by the waste heat from the ICE engine should also be gone. Working on the car in the future should be much more civilised.

[thingstodo]

The motor adapter and motor coupler have arrived!!

YAY!

Mazda MX6 Day 024 Video 010 July 23 2014 - YouTube

[thingstodo]

Will the netgain warp 11 fit into the engine bay?

Review motor before connecting the transmission adapter:
- DC motor advance to CCW
- the brushes (Helwig red-tops)
- blower shroud for the motor
- the motor terminals
- transmission adapter
- remove some aluminum from the adapter to mate to the transmission
- verify that the pins fit WELL
- mounting bolt length issues

Get the motor into the engine bay?
- hood needs to be removed

Mazda MX6 Day 027 Video 011 July 26 2014 - YouTube

[thingstodo]

- remove the hood

Get the motor into engine bay?

- remove radiator
- lift car onto ramps
- progress on ideas, but not on results

I guess the video is too long. I'll have to split it into 2 and upload each part. I'll post the video link when I get it done. 18:50 is too long
http://youtu.be/9nG9xltcprw #1
http://youtu.be/aMQpkpv27ug #2

The motor is not in the car as yet.

[thingstodo]

Raise the transmission, try to get the motor aligned with the transmission while it is being lowered into the engine bay.

The driver's side axle was removed. That did not allow enough of an angle on the transmission.

More mounts were removed until there was only one left - the fender on the driver's side. The transmission still would not flex far enough.

Almost 4 weeks of trying to get the warp 11 motor into the engine bay with the transmission already inside. Very frustrating, but no progress. I didn't feel like taking video of failure after failure, so no video. And no PROGRESS!!

Finally I accept that the transmission must come out ... I need to disconnect all of the cables, connections, the clutch ...

But there is a plan!

[thingstodo]

SOOOO ... the transmission is coming out

Mazda MX6 Day 056 Video 013 August 24 2014 - YouTube

[thingstodo]

Cut the final two cables keeping me from removing the transmission. I can reconnect them if I need them!

The transmission is out, but I could not get the driver's side axle off the car. I did get it popped out of the transmission side ... not sure if I damaged anything doing that.

The adapter plate fits nicely onto the transmission.

Details on the assembly of the motor coupler to flywheel, clutch plate and pressure plate

Measure out the length of the motor and transmission versus the size of the engine bay

The video is too long and got rejected by youtube again. I wasn't paying attention. I will post a link when I get it shortened.

16:52 is OK, 17:00 is too long .. go figure!

Perhaps the max video length starts out longer and gets shorter as you use up storage space and don't generate revenue for Youtube? The first of two is down to 16:21 and I still get an error that it is too long.

So I'll split it into 3 pieces. It will be posted when I get it done.

http://youtu.be/oyTxNJh6VZ4
http://youtu.be/zSJOu_KUOTY
http://youtu.be/bKAR5NDlbwg

The last one should be finished posting by 6 pm, Sep 14

[Daox]

I love all the updates. Keep em coming!

[thingstodo]

Tighten the allen screws on the motor adapter!

Put the motor, adapter and transmission back together

Center the motor on the clutch and transmission

Run the motor to verify no vibration

YouTube

[thingstodo]

This previous video explains the problems with the axle nut

Mazda wheel is not cooperating - YouTube

Soak down the axle nut (fifth time)

Check the impact socket - it does not appear to fit?

Use it anyway - and it WORKED! Why? Why this time?

Go over the socket set, and where I rented/borrowed it from

Mazda MX6 Day 075 Video 016 Sept 12 2014 - YouTube