Open Source Plug-In Hybrid Super-Truck

[hamsterpower]

Originally Posted by 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.

Actually that is federal law and none of this or any other engine swap is legal. But most states don't check for that and many times as long as it passes a basic road safety inspection (brakes, steering,etc) we get to drive our creations anyway.
Source: EPA letter

so much for creativity...

[elhigh]

Under the constraints of that letter, then, this Rolls-Royce Merlin engine I have lying around cannot be summarily stuffed under the hood of my Toyota.

Well, that sucks. So much for the land of the free.

Actually around these parts I'm not sure I would get stopped for that. Cops don't ask you to lift your hood, ever, unless they see a hand poking out from under the grille or smell something like a bale of weed burning on your intake manifold.

[Daox]

I know you've been working on the new swing set and solar setup, but I was wondering how this project is doing too?

[rmay635703]

Originally Posted by hamsterpower

Actually that is federal law and none of this or any other engine swap is legal. But most states don't check for that and many times as long as it passes a basic road safety inspection (brakes, steering,etc) we get to drive our creations anyway.
Source: EPA letter

so much for creativity...

We definately have to start hammering down on people who swap in an electric drivetrain.

Or better yet ignore immoral laws. I doubt the intent of that law was to dissallow reducing pollution and fuel consumption.

[bennelson]

Latest update.

I got new glow plugs. They are the modern pencil-style that are installed in parallel instead of series, but they are the older, large diameter to fit the Mercedes engine.

My buddy Steve dropped off a compression tester. It can install in either the fuel injector hole or the glow-plug hole. I'd really rather install it in the glow-plug hole, since I'm swapping out plugs anyways, and don't want to mess with the fuel injectors. (I'm slightly afraid of messing them up, not torquing them back in correctly, etc.)

The compression tester came with the right adapter for going into old VW glow-plug holes, but NOT Mercedes. Hmmm. Maybe a local auto parts store has the right adapter?

I also got a bag of flywheel bolts. I'm hoping those fit.

Also been busy just trying to earn a living. It's hard to work on super-cool projects when you also have to pay a mortgage, health insurance, etc. etc.

[bennelson]

I finally found the right contact information the other day for somebody at the state level with the Department of Transportation.

He's a guy I talked with on the phone when I was doing the electric conversion of the Geo Metro, and he got me in contact with the right folks for a "manual inspection" to exempt the Geo from pollution testing.

In a few minute conversation with him, he basically said that Electrics are easy - they simply exempt them from all pollution/smog tests.

Hybrids on the other hand.......

Anything that runs on alt. fuels still needs to be tested, but all testing is done through ODB2. They no longer have a dynometer or mechanical means of testing.

Aparently, older diesels are not tested, and regular vehicles 1995 or older (pre-ODB2) are not tested.

He was going to do a little research, and get back to me. My general feeling is the same as before - if I just use a 1995 S10, I'll be fine.

But I'm still going to get confirmation on that!

I've heard of a project or two where somebody builds something awesome, and then can't get it legally on the road. NOT a mistake I want to repeat!

[bennelson]

Just got confirmation back from the state representative.

Yep, if I use a 1995 or older truck (without getting retitled as a homebuilt, but why would I want to do that anyways!?!? Pain to insure....) then I have no problems at all - no need for any emissions testing.

Alternatively.....
Diesels in my area were not tested until 2007.
So, I COULD use a 1996 to current model year truck, as long as I used an engine from 2006 or earlier, but I would still need to take the vehicle in, have it inspected, and show them that yes, it really is an older diesel, then they would exempt me.

Easiest answer is just to use a 1995 or older truck frame. But it's good to know that if I got a really good deal on a '96 extended cab, I could still make it work!

[talonts]

Originally Posted by rmay635703

We definately have to start hammering down on people who swap in an electric drivetrain.

Or better yet ignore immoral laws. I doubt the intent of that law was to dissallow reducing pollution and fuel consumption.

The *intent*, no, but CA doesn't give a damn regardless. You can't even swap a non-certified exhaust onto a car even if it increases the efficiency of the engine and reduces emissions.

My 90 Talon got about 25mpg at 70 on the highway. By the time I got done building a new exhaust (WITH catcon), intake, engine mods, and ECU mods, it pulled down 28 (32 farther east on decent gas) at nearly double the peak hp. But if the smog guys had known what to look for, it would have failed. I was just good at making stuff look stock (paint it black, then dirty it up - you know, the reverse of ricers).

[bennelson]

The other day, I got the manual steering into the one rolling frame, which allowed me to steer it into the garage and test fit the engine.

http://www.youtube.com/watch?v=ZkI7R3K0aGo

I did test how far I had to turn the wheel. The manual steering gives 6 full rotations, while the power steering gives four.

Also, I got to stop over to see Daox tonight, and got an electric radiator fan (from a Toyota Paseo?) and a 12V DC vacuum pump.

The electric radiator fan is more efficient than the mechanical propeller on the engine. That, and I somehow misplaced one of the parts that would hold it on anyways.... The vacuum pump will be used to run the power brakes when the vehicle is on but the engine isn't, similar to how I'm using an electric vacuum pump in the Electro-Metro.

Because the engine has a mechanical vacuum pump on it, which may or may not be running while in hybrid mode, I think the simplest thing to do for the power brakes is hook both vacuum pumps up to a tee going to the vacuum reservoir, and have one-way valves on both pumps.

[Daox]

Woohoo, updates.