Paul & Sabrina's Cheap EV Conversion

[ttoyoda]

Did you know that a single 7/16" grade 8 nut is like 85 cents?! That's messed up... The nut also has that plastic ring around it (on the inside) so it won't wiggle loose. That was an extra 1 penny.

They would be made in usa then. You got the best ones. A torque wrench at sears is 12 dollars or so?? That way you can keep that kid in the big hampster exercise wheel that he has to turn to generate electricity, or else no supper.

I really appreciate all of the awesome advice that I'm getting from you guys.

Giving advice is a LOT easier than doing work. This way we get to watch YOU work, and we get the same satisfaction as if we had done the work ourselves. So really we advice-givers come out ahead on the deal.

[bennelson]

Hey Paul,

Do you have any actual photos of the CAR to post?

Motor and tranny together looks great!

[MPaulHolmes]

I had the nightmarish experience of putting in that transmission/motor. Like eating Oprah's doggie's poopoo. It was horrible!!! I need a floor jack. Also we made a youtube video. I don't know how to insert that! Here's the link.

YouTube - P&S EV Conversion #1: Connecting Motor to Transmission

[bennelson]

Cool to have that video up!

Sounded a little noisy for electric. Do you have oil in the transmission? I know Darin didn't for the first jacked-up test of the Forkenswift.



PS: I love how video posts on these things are always at 1:30 in the morning!

[MPaulHolmes]

I've been avoiding checking the trans oil because I don't have a 17mm Allen wrench. I saw one at the store, and it looks absurd. I'll buy one maybe this week. Also, the car hasn't driven since 1994 I think! At least that's when the license plate expired. the rear wheels haven't done much spinning recently and so are a little rough. That was part of the noise when hooked up to the car. I'm about to become an expert on brakes and rear axles and low rolling resistance, and the usage of freakishly big Allen wrenches.

[dremd]

Originally Posted by MPaulHolmes

I've been avoiding checking the trans oil because I don't have a 17mm Allen wrench.

OOhh OOhh I can help here

2 EcoModder Methods available

1) Buy a 17mm headed bolt place in vise, hammer in to an allen wrench ("L" Shape)

2) take a 17 mm bolt and 2 nuts that fit. Jam nut the 2 nuts together (tighten one to the other), use the closer one to take the plug out and the farther one to put it back in.

[MPaulHolmes]

Thank you!!! yahoo!!!!!!

[ttoyoda]

That video is great. Using the spacers makes a lot of sense. I wonder if it is worthwhile to run a fresh air duct to the motor air inlet from someplace that does not get water spray or get heated up.

I agree that something seems un-naturally loud.
Normally a tranny spends its whole life in the "normal" position. The bits of metal dust that are a normal part of the tranny wearing away during normal operation tend to sink to the bottom of the tranny and make a sludge with the gear oil.

When the tranny was set up on its nose, the sludge moved around and got places where it sholdn't be. If the tranny is left in the car with the drain plug open for a few days you may get rid of some of that sludge.

I sometimes flush out manual trannys. My method is to drain the gear oil. I refill the tranny with kerosene. I run the tranny with the wheels off the ground, there must be no loads on the tranny. The car cannot be driven on the street while this is being done. I shift thru all the gears, and I run it for about a minute. Then I drain the kerosene right away before the junk can settle out. Let it drip out overnight. After this I fill with gear oil and run the tranny again up on jacks for 5-10 minutes. I drain that gear oil right away also. This gear oil will look foamy or opaque when it is drained out. This is to remove traces of kerosene. Now I do the final fill with gear oil. I run this gear oil for perhaps 15 minutes just at idle to make sure any kerosene or dirt has flushed out before I put any load on the transmission.

This has worked for me in toyota trannys. I don't know if would help or hurt your VW tranny, and I only mention it because your tranny has been up on its nose. Something to think about anyway.

Also in parts of the video the drivers side halfshaft seems to have a wobble, I don't know if thats normal.

Anyway, congratulations on getting this all done and together.

[MPaulHolmes]

There was sludge in the transmission alright!!! Plus, the bolt with 2 nuts worked perfectly, and those dang bolts that were removed from the transmission were really really stuck on there! oooohh nelly!

It's draining still, right as I speak. I speak as I type. I think I'll try the kerosene approach if Kerosene isn't too expensive. Need to fix the dang brakes too. We might try to do that tomorrow. I think a good part of the noise that was coming out of the car was the bearings, which I think have some issues, so I'm going to check them.

[ttoyoda]

I think I'll try the kerosene approach if Kerosene isn't too expensive.

Around here it is sold (dispensed from a gas pump) at some Hess gas stations and people use it for kerosene space heaters. You should not have to buy it in little bottles.