Motor positioned in engine compartment

Started putting the motor/tranny into the engine compartment. Got it positioned and connected the driver sigde motor mount. Feels good. Kind of wondering if I should have tested the motor before I put it in. Not sure how I would have done that.

Making progess, two steps forward, one back

Going at it step by step per instructions. Biggest advance has been to install new clutch and fit it to electric motor. The transmission is loosely connected to the motor. I have to figure out the right bolts since the adaptor plate now in place is considerably thicker than the sheet metal on the original car.

I followed a video from the vendor of the kit I'm using to install the clutch. Felt very proud. Then I looked at the written instructions which differed mentioning that the distance between the adapter plate and the pressure plate should be 1.3" +/-.01". Oops. Had to undo and redo.\

Still, it's exciting to see the motor attached to tranny even if loosely.

I keep removing ICE stuff I could have gotten rid of before but wasn't sure what it was. I'm sure there's still more. I either don't know what it is or how I should do it.

Here are links to pics. Comments appreciated.
http://picasaweb.google.com/lh/photo/d42cTpEE7s_48WLiQqB6xg?feat=directlink
http://picasaweb.google.com/lh/photo/02kOTU2xv3peQ8EwughTvw?feat=directlink
http://picasaweb.google.com/lh/photo/zYQIzfNyNC25oYfm4stVNw?feat=directlink

Cutting trunk

Almost completed cutting the hole in the trunk for the rear battery box. There's something satisfying about watching the sparks fly when you cut metal. The conversion instructions I'm following are not great and the folks I got the kit from are not returning calls. Still I think it's ok. I'm a bit worried that I'm weakening a supporting cross-member. If I get this thing running I wonder how long before I have confidence it's going to work.

de-ICED, What next?

First, thanks to those folks on various forums who have responded to my questions. I was able to remove the starter which was the last thing connecting the engine to the tranny. They are now separated. Progress showni in last six photos in the album (click on blog title to view). Need to clean car up and figure out what to do next.

Free at last

Finally got the engine out. Took a saw to cut most of the head of that pesky bolt off and then filed until the axle came free of the transmission. Next steps are to remove a few more ICE parts and clean.

2 steps back, 0 steps forward

Still can't get the last bolt holding the axle to the tranny. Got an air compressor with an impact wrench and ratchet wrench. Put the two bolts in on either side of the problem bolt and still couldn't get the last one loose.

Wife is not happy as lack of progress means a long cold winter without being able to park in the garage.

I got the tranny disconnected and started to lift but the engine is stuck. There's not enough room. Not sure what to do next.



Here's a nice pic of a friend of Sam's who came over to check things out.

Lift-off (out) postponed

I thought the engine/tranny was connected to the frame with three engine mounts, two bolts on the side and one connection in front. After removing these three connections I started to lift. Something didn't feel right. I looked under the car (again) and noticed that the tranny seems connected to the underside.

Thanks to a post on a VWvortex forum, I now know that I need to remove 2 bolt connecting the tranny to the floor plan. Maybe tommorow.

10-9-8...3-2-1 Lift off (almost)

We (Stu and I) disconnected the axle from the outer CV joint (basically disconnected the axle from the wheel). The only thing left connecting the engine to the car were the engine bolts . We connected the lift, removed the engine bolts (holding the engine from the frame) and started to lift. The passenger side started coming up higher than the driver which didn't seem right. Also the intake manifold hit the frame. We ran out of time. But at least we're doing something interesting.

Out of gas (tank)

Stu and David came over today. Made progress. We got the gas tank out. Apparently, did not get all gas out of tank. No smoking at our house for a while please. Postponed trying to disconnect transmission from cv joint due to one lousy stinking bolt/screw (see previous post). Instead we're going to disconnect axle from wheel, lift the engine and then try to disconnect transmission from axle.

For photos see:
http://picasaweb.google.com/lh/photo/kf5VrOUFx1JQ5FvQmzBORA?feat=directlink
http://picasaweb.google.com/lh/photo/G4g56dIXwqUpbtMMJHEpJg?feat=directlink
http://picasaweb.google.com/lh/photo/9SD77l7e7LUtXk5FO1RDkA?feat=directlink
http://picasaweb.google.com/lh/photo/OItLGJQclehoJ-YVNXE-8g?feat=directlink

1 more @#$! bolt

Buddy David came over again. We got all the bolts except for one off the tranny on the passenger side. That one bolt is the only thing keeping the engine in (except the engine mounts themselves). If anyone has tips, secrets etc for hard to remove bolts, now would be a good time to share. I would be most appreciative.

We gave up on that bolt and went to the rear. We have to drop the rear axle assembly to remove the gas tank. We got both shocks/coils off and loosened the four bolts keeping the bracket in. It shouldn't be hard to get the thing off from here. Getting it back on will be another matter.

The point of no return

I've never been confident that I'd succeed with this project. However, until now, I could have the car (or what's left) towed away. I'm about to drop the rear axle. At that point, I'm not sure it can be moved. I suppose there are ways to move wrecks. Still I have the sense of getting in deeper and deeper.

Back on the Road (sort of)

Perhaps it was Independence day that inspired me to return to the car or perhaps it was my friend's Stu's enthusiasm when he showed up, but we made some progress. The great thing about Stu is that he's really happy banging away with a hammer.

We got the air compressor off. Most of all we got the exhaust disconnected from the engine. The next step is to disconnect the transmission from the axle and start lifting. I'm not sure it will come out without removing more components, but we should be able to gain better access.

How to become a car bomber

Never knew where the expletive-like expression Nuts came from. I sort of thought it had to do with getting kicked in them. Now I'm thinking it has to do with removing the air intake/exhaust manifold from a 1985 VW Cabriolet. There are something like 10 bolts to be removed. Some require crescent wrenches, others allen. With generous help we removed 8 or 9. Obviously these 8 or 9 are completely unnecessary because the thing is held very securely by the other one or two. The problem is you have to find these rusted suckers entirely by feel. They are on the back of the engine and cannot be seen from top or underneath.

After working on that for a while, I started sawing the exhaust pipe in two. Got bored with the slow progress (think I need a better saw or a power tool). So I started on the gas tank.

I had already siphoned as much fuel as I could out of the tank. But I'm guessing there's still some gas and fumes in the tank and fuel lines. As I'm working on the tank, I've got 2 halogen lights whose heat output is exceeded only by the sun. I get so hot that my goggles keep fogging. In addition I've got a more portable incandescent light using an extension cord next to me. The first think I try is to remove the fuel line from it's lowest point. The idea is to let any remaining fuel drop into a bucket. But the chances that I will accomplish this neatly are slim. So I consider what will happen if the gas (or fumes) get near the light. That's when I see myself as an unintentional car bomber. I go to move the fire extinguisher closer to me and someone's moved it (not good). By this time I decide it's time to tackle this on another day when my resevoir of patience has been replenished.

Noah did lend a hand. I had him try to remove a couple of things but they are rusty and it's going to take more strength. I'm even having a difficult time.

I keep reminding myself that all of this was to be expected and this is fun.

Progress/Regress??

My buddy Stu came over. He's an expert because he has a lot of tools and when he was young he put together a kit car. He got right in and started disconnecting stuff. We disconnected cables including the clutch. I suppose that's progress. Although perhaps since I'm still taking apart the engine, it's only regression. Stu did not want to look at the shop manual. I will say that speeds things up. However, I have no idea about some of the stuff we disconnected. I'm trying to label things, but I've got a bad feeling the labels aren't going to make sense.

I think engine removal is near. We have to disconnect the axels and the exhaust.

Mile 6

Removed the condenser tonight. Feels good when big pieces come out. Also removed the throttle cable. It's attached to some air intake thing. It looks like that air thing has got to go. Will need the throttle cable and wonder where that will go.

Still can't remove the alternator. I can pivot it. But there's a hex or some nut/screw thing I can't get loose. Not sure if I have the right tool.

Many things I'm touching look important but I have no idea what they do. This would be a good time to have help from someone who knows what they are doing. May post picture and ask questions later. Noah was helping. That was nice.

This is like a marathon. I'm on mile six. It's enough to feel a bit tired, but I'm no where even close to being able to think about the finish. I'm not to the halfway point.

The hill is getting steeper

There's a respectable empty area under the hood, but the going is getting tougher. I'm also getting a bit obsessive about this project. I don't want this car occupying my garage forever. If I make some progress every day I will eventually succeed so I'm inching along.

I've been spending some time removing bits and pieces. I've also improved the work area with better lighting. Got the rest of the air filter housing removed. Took out the radiator. Learned about the cat litter stuff for sucking up moisture.

I was starting to remove the alternator last night when I got stuck. Did I mention I'm not good at this? I disconnected the electrical and the big bolt that appears to let you adjust the tension of the belt. The belt doesn't move. Not sure what to do next. I also started to remove the AC coil but can't figure out how to remove some of the tubes connected to it. My approach is to start with soft force and then increase it as I get frustrated.

The Haynes manual is pretty helpful, but still assumes more knowledge that I have. For example it might say remove all of the vacuum hoses. How do I tell a vacuum hose? The internet is a big help. Naturally I didn't know what the alternator looked like so I used google images.

It's a go

A big thanks to Ken who came by to check out the car. He said it's a viable donor. He also recommended that I convert my carport into a professional garage (that's not what he said, it's what I heard). The work will begin this weekend.

First pics and the party hut goes up

In response to a request for pictures, I only have the one because I've never seen the car. My wife bought it. She met the owner, Jordan, at Karma VW in Decatur, GA (that's her with our future EV in the photo.) She has been out of the country for a year and is moving to Vermont, where the harsh winters will not be kind to the little Cabriolet. Jonathon, the mechanic at Karma told my wife that the car has a bit of rust and a problem with the engine, but since we'll be taking out the engine, that doesn't matter. We also won't need the exhaust pipe, which is where a lot of the rust is.

I'm very anxious to see how much rust there is on the chassis.

Tonight I put up a "party hut" - a 15x17 tent with screened sides that I hope to work under. The package say 15x17 which seemed fine for a vehicle that is 13.4x5.6. But it looks smaller. There's a crude joke in there somewhere.

I'm hoping to get the car tomorrow. Below is a view from the street looking through our carport. You can the the engine hoist and some car jacks.

Below is the party hut the car is supposed to fit under. Noah who is in the yellow shirt. He's going to be my main helper. Sam my younger son, was practicing lacrosse and making "helpful" suggestions.

Getting Ready

Originally posted on Monday May 4, 2009 on http://macevfamilyadventure.blogspot.com/

Today the adventure officially begins. Julia purchased the car for our trip.Welcome to my first post regarding the conversion of an ICE (internal combustion engine) car to an EV (electric vehicle). The background is this. I have a 12 year old son Noah who likes science. We watched “Who killed the electric vehicle”. Somehow that led to the idea of converting a normal car to an EV. My personal reason for doing this is to have a challenging, interesting, productive and educational project to do with my son. I am not doing this to have an EV. Even cursory research shows that it would be easier, cheaper and quicker to buy an existing EV than to convert one. So if all I wanted was an EV, I’d go buy one.

[I do have another motivation. I will try to make this the last political statement of this blog.] If we succeed, it will prove anyone can build an EV. I hope that this will encourage others to consider the possibilities of alternative energy that exist today. In my opinion, using less oil will do more for our country than it will for the environment. Using less gas will deprive those nations who support religious tyranny and oppose democracy of some revenue. It’s not necessarily governments who wish us ill, although Iran is no friend. Saudi Arabia is our ally, but 15 of the 19 9/11 hijackers were from that country. I like the idea of being green, but sooner or later someone somewhere will burn most of the oil. As long as it’s cheaper to use oil than alternatives, it will get burned. Emerging countries will put the immediate desire to escape poverty as a priority over the environment. Oil may be sold, but if we can decrease the demand, we will decrease the price and decrease the revenue to oil producers.

I have no mechanical skills. I can change a tire. I get nervous with jumper cables, so you can imagine my trepidation dealing at the prospect of an EV. Let me explain my worries about the E in EV. When I was a little kid (maybe 5), there was a leaky faucet in our house. A handyman was looking at it. I was looking at the handyman. This guy was no electrician. He held a brass (well it looked like brass and was metal) lamp under the sink to see the problem. Next thing I know this guy got a heck of a shock. This was no quick buzz either. He sizzled for seconds. Fortunately he was ok. He had a beer and he didn’t fix the faucet.

Fast forward to college, and I’m in a physics lab dealing with electricity and magnetism. There’s a large battery in front of me. The graduate student/lab instructor warned us not to touch both terminals simultaneously. I only touched one. He didn’t say not to lean against the wall where there was copper (well it looked like copper) pipe carrying gas to the burners in the lab. I didn’t (couldn’t) say anything while I was being shocked but everyone in the room could hear me snap, crackle and pop. So I have a pretty good concept of grounding.

So my main fear is electrocution. The others are being crushed, crashing due to brake failure or the car getting of control, and wasting $20K (my current estimate of the budget).

My wife, Julia and other son Sam (10) are very supportive. It will be interesting to see how nerves get frayed on this journey. Like any good journey, we’re enjoying the promise. I expect some hell along the way. When it’s over and the scars are healed, I hope for some good family memories.

At this point, I’ve read 2 books (Convert It! and Build your own electric vehicle) and visited a lot of websites. I’ve learned a great deal including:

• Converting an ICE to an EV is possible, but not necessarily so for me. I clearly lack the mechanical skills. I’ve been very nice to the car enthusiasts (Ken, Howard, Sam) and engineers (Karl, Steve) that I know. My plan is to be willing to outsource a lot of the work.
• An EV has specific characteristics that make it appropriate for certain uses. This is true of sports cars and pickup trucks. I’m hoping my EV can do a reliable 30 miles on a charge and a reliable 45 mph. From what I read, this is entirely realistic. If it achieves this, it can easily be my commuting vehicle.
• In principle, the conversion is easy. Get an appropriate vehicle; remove the ICE including the unnecessary stuff (gas tank, exhaust etc); put in a new motor and a lot of batteries and go. But there are details. The car is going to weigh more (probably 800 lbs more in our case) so it needs good brakes and suspension. The distribution of weight needs to be considered to maintain safe handling properties.

This project is going to be difficult for us, so my plan is to make it as easy as possible. To this end, my plan is to buy a kit. Kits include combinations of electrical stuff (more on this later) that work together. More complete ones include boxes to hold the batteries. Most important is the adapter that connects the motor to the transmission. This is custom for the vehicle.

Small pickups are considered the easiest and I gave a lot of thought to this. They have room for the batteries and are designed for the extra load. But I don’t want a pickup. So my research led me to https://wtcmail.wilmingtontrust.com/exchweb/bin/redir.asp?URL=http://www.electroauto.com/ the folks who wrote the Convert IT! Book. That led me to choose the Volkswagen Cabriolet. A/C is a drain on the battery, so I thought a convertible would be nice. For a reason that is secret to me, the Electro Automotive kit only works with Cabriolets through 1993.

So I began shopping. The winner was Craigslist. We found a 1985 Cabriolet. It’s in the shop. It needs a brake line weld (whatever that is). The engine needs work, but since we’re throwing that out, we don’t care. Price of car and repair: $950. I’m going to try to document the cost as we go. The books were about $45. Only $19,000 left before breaking the budget.

The next steps are to bring our baby home from the hospital and put together a space to work on it.