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.

Vacuum Brakes booster pump kit arrived.

Work plan updated: activity last night…

Took out the drive shafts, they need new boots. Need to inspect the CV joints and replace if necessary.

Removed starter from transmission – won’t be needing that, to be put in the spares pile for one of the no-EV VW’s.

Removed transmission from bus. The late model type 2 is soooo easy verses an early model (w/reduction boxes!)

The input shaft is loose, so needs repair, otherwise the oil was clean, no leaks or signs of other trouble. We give the case a really good clean. Now its out can start working out the final alignments for the motor mount.