Paul & Sabrina's Cheap EV Conversion

[ttoyoda]

I am amazed how well you have done considering how few tools you have available to work with. Good job!
I would have never dared try to make those spacers without a lathe to center drill them and face off. I am not sure from your pictures, but do you have flat washers between the bolt head or nut and the original VW transaxle? If not you might consider putting them in to prevent the bolt from locally chewing into/deforming the transaxle. Are you going to hook up a mess of batteries just temporarily and drive down the street?

[bennelson]

I am getting a little jealous here.

Paul's conversion is leaving mine in the dust....

[ttoyoda]

I don't see why. You already have a cool electric motorcycle. And a video of it. And your neighbor on tape saying it is the "coolest thing evah 111eleventy!"

When Paul gets HIS project done and has a video of his neighbor, THEN you can be jealous. I am jealous of both of you.

I have to get off the computer and MAKE something.

[MPaulHolmes]

Originally Posted by ttoyoda

I am not sure from your pictures, but do you have flat washers between the bolt head or nut and the original VW transaxle? If not you might consider putting them in to prevent the bolt from locally chewing into/deforming the transaxle.

hmm. I think I'll cut this message short and head out to Tacoma Screw... I was going there anyway, I swear I was.

And will I hook up some batteries and drive down the road? Oh man, that would be awesome. I only have 1 12v battery right now, so it would be really slow. Also, I need to get the controller hooked up.

I'm back, and I tested it and things went really well! No wiggle. Spray painting the holes worked like crap.

[ttoyoda]

I'm back, and I tested it and things went really well! No wiggle. Spray painting the holes worked like crap.

Cool, now where are the pics?

IF you get a chance you might lookup the torque values for your grade and diameter and thread pitch of bolt, and torque them to that value. That would give you the best stiffness of your setup when you go to full power.

Is paint flowing away from where you try to spray it? Maybe there is penetraing oil residue or silicon spray residue somewhere? The cheap carburetor cleaner from walmart helps get it off. Don't get it on your skin, you will need your liver for a long time yet.

[ttoyoda]

And will I hook up some batteries and drive down the road? Oh man, that would be awesome. I only have 1 12v battery right now, so it would be really slow. Also, I need to get the controller hooked up.

I always try to do little test like that, because it keeps me motivated, and it's some fun interspersed with work. Also cheaper than drinking.

[dremd]

But don't get disappointed if it doesn't work at 12 Volts; my golf cart wouldn't budge (even with the wheels off the ground).

[MPaulHolmes]

Originally Posted by ttoyoda

Cool, now where are the pics?

We're putting together a short video too, where we run the motor and transmission. Also, I had to cut the corners off of the plate attached to the motor because I couldn't get the bolts through the stupid holes to mount to the transmission. Now, I'm about to do the FINAL test. I repeat, the FINAL test!!! before putting the transmission back in the car. I would feel a heck of a lot better if the motor wasn't just floating there, but also had some sort of support under it, to cut down on the force on those poor little bolts. That would kick so much bottom! Maybe some angle iron. I don't know!!! argh!

[ttoyoda]

We're putting together a short video too, where we run the motor and trans.

That looks soooo cool
It must have taken a lot of work to figure out how to make the bolts thru the spacers miss the rim of the tranny, and still get it centered.
Is it hard to change the oil seals where the halfshaft stubs come out?

[dremd]

Originally Posted by MPaulHolmes

I would feel a heck of a lot better if the motor wasn't just floating there, but also had some sort of support under it, to cut down on the force on those poor little bolts. That would kick so much bottom! Maybe some angle iron. I don't know!!! argh!

Not that it helps much, but remember that VW designed the motor/ trans to counter balance each other. the mounts under the transaxle are designed to hold the weight, the single mount on the "nose cone" of the transmission is designed to only hold the engine/ transaxle from flopping forward/ backwards (under acceleration/ engine braking is how they are typically broken).

SO what does that mean for you?
A test is required.
Balance the engine/ transaxle (on anything a 2/4, jack, pipe all would be fine), and if a great deal of force is required to hold either end up; I would definitely add some sort of brace to the motor. Otherwise you will be breaking motor mounts all the time.

Hope that helps.

And just a thought; you should test it in the horizontal position prior to mounting it in the car. Something could flex, fall, something . . . . .