Open Source Plug-In Hybrid Super-Truck

[a8ksh4]

How are you getting around the smog regulations where you live? In Ca, I have to swap a newer motor than is already in my truck and have to preserve all of the emissions stuff from the newer motor, if I want to change it. I wonder if I could pull my engine after installing a motor, get the truck registered as an electric, and then go back and install a little diesel engine.

If you really leverage the batteries in your setup, and enable regen, then you might be able to only have a small engine, like one of the kubota tractor motors (or just use what you have). I'm thinking that you could use the motor with or without the engine to help with acceleration, and, any time you are just cruising, you could use the engine for forward driving power and crank up the regen on the motor for the next time you need to accelerate.

With this kind of setup, you'd set up your throttle so that it limits out with the engine 1/4 of the way through and then activates a potentiometer to start applying electrical power to the motor. any time you are at cruising speed, your throttle is backed off into the first 1/4 range and this activates regen on the motor until your batteries are charged. This might be a seamless way to keep your engine at peak efficiency/high load and automate integration/function of the motor with the engine.

Ohhhh... I don't think I like the shift knob rotator motor throttle idea, unless it has a cutoff switch. I can imaging running into a corner hot, grabbing the shift knob to drop down to 2nd gear, and accidentally applying power to the motor, breaking the rear end loose or something... Might need to find a way to do it so that you don't apply pressure to the throttle when you shift. Also, I've heard about residual weight from resting a hand on the shift stick causing wear to trans parts... Not sure about this, but it's worth considering.

[Daox]

I have a 12V vacuum pump that might work for you. I don't know if its large enough for a vehicle or not, but picked it up because it was super cheap. It will need a vacuum switch added to it.

[bennelson]

Originally Posted by Daox

I have a 12V vacuum pump that might work for you.

Hey, that would be great! It's been to long since seeing you anyways! We need to get together soon.

[bennelson]

Originally Posted by a8ksh4

How are you getting around the smog regulations where you live?...

Ohhhh... I don't think I like the shift knob rotator motor throttle idea, unless it has a cutoff switch....Might need to find a way to do it so that you don't apply pressure to the throttle when you shift...

When I did the conversion of my Geo Metro to electric and had to jump through the legal hoops, I found out that ANY diesel conversion in my area is EXEMPT from smog testing. Also, vehicles older than 1996 (pre-OBDII) are exempt, and the project truck is a '95.

As for the throttle on the stick shift, it could also be a trigger, rather than rotary, or I could simply always apply a slight back-pressure whenever I shift. On my motorcycle, it has an electronic twist throttle, and it doesn't change by accident while steering the cycle. It only twists when I conciously accelerate.

[bennelson]

Guess what I found on my doorstop when I finally made it home from the Mother Earth News Fair?

S10 Manual Steering!



It doesn't look like much, but this MANUAL steering gear box should allow me to steer the truck WITHOUT needing power from an engine to run the power steering gear.

It's supposed to be a "bolt-on" replacement. The idea is that both the power steering box and the manual gear box are identical as far as where their ins and outs are, and how they attach to the frame.

I'm real busy with work the rest of the week, so I won't be able to play with the steering for at least a few days, but I look forward to working steering!

PS: What do you guys think of me doing a Kickstarter or Indegogo social fund-raiser to get money for this project? I really WOULD like to make this a big project that gets lots of press, makes it out to all the blogs, and hopefully inspire a few other people to do it too. Having some money for real batteries sure would help a lot!

[Daox]

Its worth a shot.

[bennelson]

Did some work on the engine.
It's actually been a couple of YEARS now that it's been kicking around! However, it DID run when I pulled it from the Mercedes 240D.

My buddy Steve has lots of old-school experience with diesels, so he stopped by to lend a hand.

Together, we got it running.

http://www.youtube.com/watch?v=3clXwcCKLMc

It needs a new water pump, and will end up with a few modifications before its installed in the project truck.

[bennelson]

I mail-ordered a new water pump. Got it the other day, and installed it today.

I've never done one of these before, but I just followed the directions, removed the old gasket, cleaned it all, put the new gasket on with some tacky goo, and bolted it all back together.

Nice and shiny!

Normally, the fan blades would mount right on the water pump, but I think I will probably convert it to an electric fan anyways.

http://www.youtube.com/watch?v=yZJEE2KKcAg

[bennelson]

I ordered a manual steering gearbox a little while ago.

Here's a quick video comparing the power steering to manual steering.

http://www.youtube.com/watch?v=S46fXYk392Q

It seems to me that going to manual steering is the absolute simplest way to go. No extra electric motor, no complexity. Nice and simple, saves weight, and the truck will drive the same whether running on the electric motor or the diesel engine.

[cRiPpLe_rOoStEr]

Originally Posted by bennelson

Normally, the fan blades would mount right on the water pump, but I think I will probably convert it to an electric fan anyways.

That's way better than a mech fan.