Edited together some before and after pictures of the paint work

Vacuum pump wired up – only temporary wiring will clean up and do it nicely.

Found major air leak from hose connected to the servo, replaced and now it sucks correctly and stops very well!

Disaster! – While tightening the nuts on the Main Contactor the stud twisted off, M8 is big, but copper is soft… and I guess I’m stronger than I think!

Good news – I designed my system with a certain degree of redundancy in this regard, I added the second contactor for protection and so in an emergency I could bypass or swap the defective contactor and still drive it. So thats what I did. Bypassed it.

First major outing, took StealthBus from Cumming, GA to Lawrenceville, GA – 26 miles in total.

Starting pack voltage 154v, finish 143v (pretty close to 80% DOD).

Plugged in for full charge, 5hrs at 13A from wall plug the pack back up to 160v – cutoff set at 172.8v (per specs).

Need to hook up a 30A 220V circuit to the garage, so I can charge faster, but 115A/15A ok for now.

FIRST TEST DRIVE – WOO HOO!

New calipers fit nicely, these 4 piston racing brakes should control the electric beastie in the back!

Complete basic installation of the vacuum pump, need about 6 inches more vacuum hose and to install the control relay.

Completed wiring, positioned all batteries, and fired up the complete system…. *GIGGLE* *HEHEHE*

High voltage cables on controller

Motor and controller connected and ready to go

Battery wiring setup

Circuit breaker bracket in position

Dash mounting test of main gauges

The bus getting some elevation

Inspection of the brake servo

Cool under bus shot of complete drive train

Damn Volkswagen’s – even with an electric motor they still leak oil!

Motor mounting plates assembled, basic alignment completed.

Connected flywheel (lightened… I might add, very nice), clutch kit and ran on bench with transmission:

Motor – Motor coupler – Transmission mounting:

Rear battery rack:

Controller panel in place:

New drive shafts:

Motor bench test, first test of motor. following the bench test guidelines very closely:

Crank shaft and sprocket welded and mounted

Motor test with flywheel

Transmission – found intact circlip! JOY.

Transmission cleaned and input shaft repaired.