update: here they are installed. Works very well. One small issue is the fitting on the master cylinder is a little loose. I had to route the hose so there was no bending pressure either way on the fitting.
Wednesday, September 30, 2009
Brakes
As the vacuum pump went away with the engine, the brakes need a new source of vacuum to be effective. I ordered a 12V vacuum pump kit with reservoir from EVSource today, along with a 75A relay.
update: here they are installed. Works very well. One small issue is the fitting on the master cylinder is a little loose. I had to route the hose so there was no bending pressure either way on the fitting.
update: here they are installed. Works very well. One small issue is the fitting on the master cylinder is a little loose. I had to route the hose so there was no bending pressure either way on the fitting.
Rear Battery Box mounting
I made brackets for mounting the side boxes, to be welded both to the boxes and to the frame.
Thursday, September 24, 2009
Battery Box construction
Today I bought steel for the battery box: 50mm and 25mm angle iron along with one sheet of 1.6mm sheet metal. Started in on the fabrication too.
The 50mm angle iron connect the three boxes. The boxes will have 6 mount points, 4 where the gas tank was attached and 2 new ones for the smaller side boxes.
Managed to weld the frame and cut the sheets for the sides.
The 50mm angle iron connect the three boxes. The boxes will have 6 mount points, 4 where the gas tank was attached and 2 new ones for the smaller side boxes.
Managed to weld the frame and cut the sheets for the sides.
Wednesday, September 23, 2009
Power Steering Pump
The land rover came with power steering, but the pump went away with the engine. So today I ordered a used Toyota electric power steering pump, designed for the MR2 sports car, via eBay. The total cost was $285.
update: One of the mounting holes was broken in transit. I was able to make a mount which sandwiches the arm with the broken end.
update: One of the mounting holes was broken in transit. I was able to make a mount which sandwiches the arm with the broken end.
Thin metal welding
Found more rusted out sheet-metal. The rear-most cross member, which is enveloped in the rear bumper, had some big holes.
I use a stic welder, and I am not very good welding thin stuff. This took some time and is not very pretty, even after grinding. Maybe painting will help.
I use a stic welder, and I am not very good welding thin stuff. This took some time and is not very pretty, even after grinding. Maybe painting will help.
Tuesday, September 22, 2009
Start on Battery Box
Now I start on some EV specific work, namely the lower rear battery box. This will sit where the gas tank once was. Rather than make a box based on the dimensions of a particular battery brand/model, I will simply make it as big as space on the car allows. First step is to cut out the rear deck, which is very rusted already.
Rather than one box, there will be three, arranged like saddle bags around the frame members.
The size is limited by the rear bumper, the frame cross-member, and the rear wheels.
Rather than one box, there will be three, arranged like saddle bags around the frame members.
Saturday, September 19, 2009
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