Open Source Plug-In Hybrid Super-Truck

[Slow_s10]

Thats awesome that you have so much of the stuff you need just laying around. Man I need a cooler garage, all of the stuff that I have laying around is usless for these kinds of projects.

[bennelson]

Here's a bit of what I've been up to lately in video format.

http://www.youtube.com/watch?v=00aOF4V-w7U

[Ryland]

How about using the heat tape on the fuel line instead of heating the whole tank? that way the fuel going to the fuel pump is heated quickly, the fuel returned to the tank is also warm but you are not trying to heat 70 pounds of fuel all at once, same idea at the heat exchanger that uses warm engine coolant to heat the fuel supply line by having a coolant line surrounding the fuel line that is running back to the fuel tank, something like that could also be part of an engine block heater with a small preheat pump for the fuel line.

[bennelson]

If I did use heat tape for heating the tank, it's because it's AC powered.
It could just sit there gently warming fuel from wall power (maybe even on a timer, etc.)

Something else would be used for heating fuel lines (while away from AC power) - 12VDC or the coolant surrounding a fuel line truck.

[rmay635703]

Originally Posted by bennelson

If I did use heat tape for heating the tank, it's because it's AC powered.
.

Tap the heating element directly, can't say i've ever seen a heating element that cared what type of current was going through (AC/DC) then keep a thermostat and a switch to turn it on and off, keep the existing goodies for when your at home and the direct dummy switch for the road.

[cRiPpLe_rOoStEr]

Originally Posted by bennelson

Here's what I'm thinking for the throttle.

I'd hack an e-cycle twist throttle, combine it with a stick shift knob, and mount it to the stick.

The driver can then both shift and e-ccelerate with one hand.

That sounds good

[bennelson]

Yesterday, I talked on the phone a bit with a guy I know in western Wisconsin who did an EV Hot-Rod.

What's neat about it is that it has a DC motor rigged directly to the rear differential. SO, it's direct-drive AND rear-wheel drive, which is exactly what I want to do with the pickup truck. (Except that mine will just happen to have a transmission and diesel engine in front of the motor.)

He gave me a DVD a while back that he made which had a slideshow on it about the construction of the car. I looked through it for ideas in how to mount my motor.

I pulled these stills to show you what he did, and might give ideas for what I may do. So, take a look at these first....







You'll notice a few things in the photos.
What nice mounts those are for the motor.
That the motor goes directly to the differential
and
That the motor sticks up through the finished floor, between the bucket seats.

On my project, I want the motor to be directly behind the transmission. The motor will be coupled as directly to it as possible. I'm imagining something similar to the splined double-female connector I used to couple the motor to the transmission in the Electro-Metro.




A "Chinese Finger Trap" connector could fit between the transmission and the motor. The transmission is mounted to the frame, and the motor would be mounted to the frame in a way similar to the hot-rod shown above.

Since the truck is front-engine, I'll still need a drive-shaft to reach from the electric motor to the differential. This will re-use the original drive-shaft, only shortened, and the front end will have to be modified to fit the electric motor.

On the hot-rod, you can also see how the motor sticks up through the floor, between the seats. My preliminary measurements seem to show that basically the same thing is going to happen in the truck.

I think that if I swap out the bench seat for bucket seats, it all works out fine. I'll have to sawzall a hole in the floor (which I did in the Metro for the back-seat battery box) and then install a "hump" cover over the top of it.

For more info on that hot-rod, you can see it at: EnviroTech: Lightning Electric Car The motor in it is a 9" Netgain and it's running a Netgain brand 1000 amp controller at 156V

The other thing I've started thinking about is steering. The truck has power brakes and power steering, but manual everything else. I've already dealt with converting power brakes to electric on EVs, so that's not an issue. The Metro had manual steering, which I always liked on that car, but I need to figure out the best way to deal with the power steering in the truck.

Seems to me there's three ways to go about it.
Add an electric motor to run the power steering.
Loop and cap off the power steering hoses.
Replace with a manual steering rack.

Is that about it? Am I missing any other options?

At this point, I would be leaning towards installing a manual steering rack. It's the simplest setup and the truck would steer the exact same whether in diesel, EV, or hybrid mode.

I've never converted steering over like that before. Sounds like some hard mechanics work. I've also heard that manual steering was NOT available for the Gen2 S10s, but that manual steering off Gen1 S10s will fit Gen2, but that they are getting hard to find.

Your thoughts on steering for the project?

[zsnemeth]

Originally Posted by bennelson

Here's what I'm thinking for the throttle.

I'd hack an e-cycle twist throttle, combine it with a stick shift knob, and mount it to the stick.

The driver can then both shift and e-ccelerate with one hand.

Originally Posted by bennelson

Seems to me there's three ways to go about it.

- Add an electric motor to run the power steering.

- Loop and cap off the power steering hoses.

- Replace with a manual steering rack.

Your thoughts on steering for the project?

I'd say the manual steering rack is not compatible with Your e-accelerator idea. Generally, i don't like the e-acc., You should use just the pedal.

This truck will be heavy, what if You need both hands for steering?

[Gealii]

as far as steering goes would this be what you mean?
1982-95 Chevy S10/GMC Sonoma R&P kit (Black) | 1982-2004 Chevrolet 2WD S-10 & Blazer's | Chevy Truck Steering and Rack & Pinion Kits | Seach By Vehicle | Unisteer Performance
There are install instructions towards the bottom of the description

[mechman600]

Originally Posted by zsnemeth

I'd say the manual steering rack is not compatible with Your e-accelerator idea.

Imagine trying to turn the wheel with a manual rack at a slow speed AND using the e-throttle on the gear lever at the same time.