Front trays completed, Billie and Mike added threaded rod and bar across the top to hold the batteries down – lookin’ nice! Completed heat shrink and battery boot assembly for battery interconnects. Located fuse and master breaker, completed front battery tray interconnect cable.
Back tray completed, ready to be bolted.
Motor mount wrapped, weld, grind, weld, grind, weld, grind, etc and primed.
Reassembled mount onto motor, shaft key inserted and fixed to coupler.
Lightened flywheel bolted on, clutch reassembled (nice German made – quality stuff…).
Transmission resealed and complete.
Attached mount to motor, transmission to mount, support bar to rear of motor and then the whole package was mounted for final assembly to the bus.
Brought heat gun and heat shrink (from Frys) to finish battery cables, heat gun lasted 3 cables and then stopped working!
Decided to reuse the radio slot for the three main meters: 80-180v (Main Pack), 0-1000A (Main Pack), 6-16v (Aux Battery). Brought a very nice trim piece from Bus Boys in CA, can get these to fit without major modification to radio slot.
Started making first battery and motor cables – needs some heatsink to make these nice and tight.
Hammer crimper is crude but very effective!
Cable arrived from Revolt
10ft of 4/0
50ft of 2/0
It’s all bright orange!
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:
Measured up for battery racks – ordered angle iron.
Clean the transmission within an inch of it’s life – bound to leak now 🙂
Order in for new drive shafts from ~SoCal
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.
Evening at Stockornaut: Crank shaft end piece back from machine shop
Sourced a large 1.125 diameter sprocket which will be welded and sleeved with the crack shaft for very solid connection.
Will use a resurfaced flywheel (original German) and brand new OE Clutch kit.
Templates for the transmission and motor being send to metal laser cut shop for the end mounting plates fabrication.
Other component updates:
Transmission – will replace main seals and investigate loose shaft, believe should be just a Circlip – if we find a whole circlip in the bottom of case – JOY, if not… mmmm…
Drive shafts, CV joints, boots – will replace with all new pre-assembled unit from So Cal, this removes any doubt about the previous condition.
Brakes – waiting on delivery of mounting brackets for upgraded front disc brakes
Batteries racks – design modification to balance to load, plan on using basic angle iron to build frame to hold batteries in place bolted through the floor.
Completed mock up and placement of primary components, due to cable bending and physical heights of the connections some components needed to be relocated to keep the wiring tidy.
Added fuses to shunt and voltmeter inputs, so all connections from primary to secondary systems are protected. 3 x 1A fuses protect Ammeter and Traction pack voltages.
Need to add diodes to all relay coils.
Acquired basic 15W solar panel – as a experimental aux battery charger.
Requires addition of a basic solar charge controller to be usable long term.