Open Source Plug-In Hybrid Super-Truck

[cRiPpLe_rOoStEr]

There was never any S-10 officially-released back here in Brazil without power-steering, but I've once seen one fitted with a Ford Maverick steering box. BTW if I were going to delete the power steering I'd consider to mount a planetary-gear setup to make it require less effort to steer.

[Slow_s10]

The factory manual boxes have a much lower ratio than the power ones do. I was actually out working on my truck in the garage yesterday and I was easily able to spin the wheel of my truck with one hand while it was parked in the garage, even with the wide 235 tires that I have on it right now.

[bennelson]

If anyone knows a good source for a manual gear box, please let me know.

I haven't had much luck finding one at a local salvage yard. They are a little pricey mail ordering a new or rebuilt, and always want a core (which I don't have, I have the POWER version.)

I'd love to get one used for under $100. Donations welcome as well!

[Slow_s10]

Yeah I forget how hard they are to find. I just checked a couple online stores and I was suprised when I saw that the manual boxes were going for around $230 and the power ones were going for less than $100. That seems pretty backwards to me but I guess that's just the law of supply and demand in action. It's just funny to think that the steering box in my truck is worth close to half of what I paid for it.

[bennelson]

Hoping to find the right steering box for the truck at an auto swap meet this weekend. Also looking for steel rims for snow tires for my wife's Prius.

[bennelson]

Hmm.

Didn't really find the parts I was looking for at the swap-meet, but I did find a broad-axe and a pair of 15" full moon hub-caps, one of which I have lost already! (Maybe SCREWING them on to the rims would be better than the clips those things use.)

Here's a video I shot with my phone the other day refamiliarizing myself with what I have for the clutch and interfacing the engine and transmission.

http://www.youtube.com/watch?v=Dd_jEzIyRA0

A little more about it and a few photos of some electric cars that were around while I was doing that at MY BLOG

[bennelson]

I was also playing around a little while back with putting fiberglass over foam, basically "learning-by-doing", which usually works pretty well for me.

http://300mpg.org/2013/03/08/diy-ton...at-still-ugly/

Mostly, I learned that I don't like working with fiberglass.

I tried building a tonneau cover, with the idea that it was practice for a possible future aero-cap.

Since going through all that, I realized that I am much better with certain materials than others. My father has built several cedar-strip canoes, and I figure that canoe technology may actually be a better fit for me and this project. I started a new thread on aerodynamics on this project at: http://ecomodder.com/forum/showthrea...cap-25662.html

[dodgedartgt]

Hi Ben,

Just watched your quick video. Have you contacted Kennedy Engineering? They are ALL about trans adapters!
The way I see it, you have three options;
a) Use the S10 bellhousing and add an adapter to the Merc engine's bell mounting plate
b) Use the Merc manual bellhousing and adapt it to the T5
c) Make a new bell mounting plate for the engine with the S10 bell pattern.
Points to consider are the location of the starter in relation to the flywheel's gear ring;
Length of the T5's input shaft and depth of engagement when bolted up to whatever adapter combo you use.
My .02 and food for thought,
Mike in FL

[bennelson]

I just found a manual steering box.

I did an online parts search and called a few places. It's amazing how many are listed as manual gears, but when the guy actually checks, they are power steering...

Anyways, called a recycling center in Nebraska, and the guy was nice enough to actually go look and confirm that it was indeed the MANUAL steering gear. It should be in the mail later today, and here next week!

Once I have steering, I should be able to to MOVE the truck! At that point, I may be able to move it into the garage, lift the bed straight up and off, etc.

Mike in FL, thanks for your input.
I don't think option B will work, as I don't have the Mercedes MANUAL transmission bell housing. The engine came mounted to an automatic tranny. I do have the bell housing from that, but I don't think that helps.

That spacer part that I had on the engine in the video is removable. I don't see why I couldn't make a custom piece that REPLACES that which the Chevy bell-housing would mount to. Of course length of the transmission shaft is critical.

The starter not matching up between the engine and bellhousing is pretty obvious when everything is together. Anybody have advice for that one?

Seems to me that it might be easier to carve away at the aluminum of the bellhousing then to try to mount the starter motor on the "wrong" side of the engine, due to where mounting bolt holes are and other things in the way on the other side of the engine.

[dodgedartgt]

Ben,

Is the bellhousing on the automatic removable from the trans? If so, then modify it to accept the T5. That should be easier than relocating the starter. It already held a torque converter, so I should think that it will hold the clutch pack and flywheel no probx.

Mike in FL