Sunday, December 6, 2009
2 steps back, 0 steps forward
Wife is not happy as lack of progress means a long cold winter without being able to park in the garage.
Tuesday, September 29, 2009
Monday, September 28, 2009
Lift-off (out) postponed
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.
Sunday, September 27, 2009
10-9-8...3-2-1 Lift off (almost)
Friday, August 21, 2009
Out of gas (tank)
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
Wednesday, July 29, 2009
1 more @#$! bolt
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.
Monday, July 27, 2009
The point of no return
A tribute to engineers
Why they need so many types and sizes of bolts is beyond me, but there must be a reason.
Thursday, July 23, 2009
Getting there....
Wednesday, July 22, 2009
What a mess!
Without that bit, we went to remove the gas tank. To remove the gas tank, we have to lower the axle. We took off the wheels and disconnected the brake lines. We got stuck removing the bolt for the coil/shock absorber and called it a night.
Garage is looking pretty bad.
Monday, July 6, 2009
Back on the Road (sort of)
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.
Sunday, June 21, 2009
Stalled
The intake/exhaust manifold stubbornly clings to the engine. I'm not making progress with that. I'm also not sure about removing the gas tank. It's about time to call for help.
Tuesday, June 9, 2009
How to become a car bomber
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.
Monday, June 8, 2009
Pressure is on
I'm at a point where care seems to be in order. Until now, I won't need what I'm removing. When I remove the engine the transmission will come out and I'll need that. So instead of working on the engine, Saturday I disconnected the exhaust from the chassis. It's still one long (10 ft) pipe. There appear to be sections, but I can't see how to disconnect them. It's above a major crossbar that I'd rather not fool with (less the entire car collapse on me). I may just take a hacksaw to the exhaust. Tonight I'm back to the engine.
I also got a message from my pals at Electo Automotive that lots of stuff has shipped (adaptor, motor mounts, weather stripping), but not the motor or controller. So the pressure is mounting.
Saturday, June 6, 2009
Webcam hooked up
My main hope was to provide some entertainment but possibly use it so that people could see what I'm doing while they are helping me. If you have comments, let me know. If you think you'd check it out from time to time, but the current quality is too poor I might upgrade. Thanks.
http://maceyev.blogsite.org/img/main_fs.htm
Thursday, June 4, 2009
Progress/Regress??
I think engine removal is near. We have to disconnect the axels and the exhaust.
Wednesday, June 3, 2009
Mile 6
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.
Friday, May 29, 2009
The hill is getting steeper
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.
Monday, May 25, 2009
The de-ICEing begins
Noah got into it and was a real help. There are about 50 steps to remove the engine. We've done about 6. We finished trying to remove the air filter housing. He figured out where it is - in our Cabriolet it was in a different place than in the Golf the manual showed. He did a lot of the unscrewing. Best of all, he said he was having fun.
Got gas over me and the garage. I didn't expect gas in the air filter housing but maybe the fuel injectors start combining the mix there. What do I know? I'm happy there hasn't been a fire, electrocution, collapse, injury etc. I'm kind of stuck figuring out the last connection to the air filter. I posted a question on VWVortex http://forums.vwvortex.com/zerothread?id=4406090.
Tuesday, May 19, 2009
It's a go
Sunday, May 17, 2009
Greased Lightning
Tuesday, May 12, 2009
Major Disappointment. Ditching Car #1
All I wanted was a good chassis, brakes and transmission (including clutch). There was rust on the exhaust, but that's ok because that would go anyway. So we bought the car based on the evaluation of the repair shop.
From what I understand, the original brakes use a rubber strip and this had been replaced by a weld (solid). We need good brakes since the car will be much heavier after conversion. So the mechanic wanted to restore the brakes to the original design. We agreed to pay for the brake job and to have the a/c drained.
The car was supposed to be ready last Thursday. Today, I hear that they can't fix the brakes on one side. Also the clutch isn't working properly. I have lost confidence in the repair shop. They missed the clutch on their evaluation and they can't fix the brakes. So I think it's time to cut my losses on this vehicle, a major disappointment.
So if you know of a VW Cabriolet with good body, brakes and transmission let me know.
Monday, May 11, 2009
First pics and the party hut goes up
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.
Sunday, May 10, 2009
The Conflict Begins
Car not ready from shop. Spent yesterday evening assembling the engine hoist. There's a special place in hell for the graphic designers or printers or whoever makes the instruction manuals for so many things produced. Who can read 2 pt type? I'll be right there with them. There's also a place for the consumer who doesn't read the instructions carefully. After a mis-step and some dis-assembly, it's perfect. However, the mis-step on this easy first item, does not help my confidence. I'll chalk it up to a lesson learned.
Julia is already commenting about the time I'm spending on it (Just wait). Hey Julia - I have one word for you: Doll-House! Who knew blogging could be fun.
So there's going to be conflict. I'm not talking about marriage. It's the weekend. DO I go to the lake and ski/mountain bike or work on the car. Life's tough.
Nesting
The car, which I haven't seen, is scheduled to arrive Thursday. I'm itching to see how much (little) rust there is.
This conversion reminds me of having children. Except this time I'm the one going through the pain. The nesting urge was overwhelming tonight. I need tools and a space to work. The plan is to work on the car on the patio behind our garage (there's no back to our garage). It'll be hot and there will be a lot of mosquitos. So I ordered the Texsport Party Hut Screen Arbor. It's a 15x17. The walls are screened. It's scheduled to arrive 5/11. So I have a week with the bugs. If I get lucky the West Nile will counter the Swine flu.
Tonight I went to Pep boys (Babies R Us). I got the shop manual for the VW (the What to Expect when you're expecting or the Pediatricians Guide). This is the Haynes Repair Manual for 1975-1992. According to the cover, it "includes essential information for today's more complex vehicles." I turned to the part about engine removal. I immediately got that "I'm in way over my head" feeling. For example, step three "If the vehicle is fuel-injected, relieve the fuel system pressure (see Chapter 4). I don't know how to tell if it's fuel injected. Maybe it will have a sign on it.
But that's not the bad part. I turn to Chapter 4. Here are the 4 steps for fuel pressure relief (after the dire warnings about gasoline): (1) Before disconnecting the fuel line, the fuel pressure must be released from the fuel line to eliminate any danger of fire or contamination. (2) Remove the fuel pump fuse to temporarily disable the fuel pump. (3) Allow the engine to run until it stalls. (4) Disconnect the negative battery cable before performing any work on the fuel system.
So when do I start the engine? Before step 1 or 3? It seems to me that relieving fuel pressure is indeed work on the fuel system so should I perform step 4 first - clearly not or it would be step 1...but then there's that warning about the fuel. Well I joined VWVortex.com. Let's see if a post produces an answer.
Also, bought miscellanous stuff including shop rags (baby wipes), engine cleaner (disinfectant), eye protection, WD-40 (baby oil). The big expenses were an engine hoist and a creeper (that thing mechanics lie on to roll under the car) and a cool looking jack. Total damage at Pep Boys: about $250 after a $40 rebate. Maybe I'll be able to sell some of this stuff later.
My new best friend is Bill Lentfer at Electro Automotive, the firm that provides the conversion kit. He's been great at answering my questions. Once I called and hung up without leaving a message. He called me anyway. We went over the prices and the options. His attentiveness was so great that I wasn't even annoyed (maybe a tiny bit) that the prices are different from those on the price list on their website. This will be the big check and will get its own post soon. Let me just say that I'm not sending the check until I see the car.
Current total $1,410. Think of all the money I'm going to save on gas...haha. And hey, who can put a price on a baby?
Also, Noah seems to be losing interest. I'm hoping it will be reignited when the car arrives.
Getting Ready
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.