tag:blogger.com,1999:blog-60356473901244890622024-02-19T08:54:52.954-08:00Electric S2000Juan Ehringerhttp://www.blogger.com/profile/13103228343094439116noreply@blogger.comBlogger12125tag:blogger.com,1999:blog-6035647390124489062.post-71208385903104737592012-09-16T09:48:00.001-07:002012-09-16T09:48:52.912-07:00Hey everyoneI haven't updated this blog for a long time.<div>
This is because I generally post the information on forums much more often than I post on this blog. </div>
<div>
When I post on this blog I kinda feel like I am talking to myself, plus I enjoy having people give me some suggestions on forums. </div>
<div>
<br /></div>
<div>
So eventually I will update this blog (probably when I finish in a month or so), but until then please head over to my build thread on an S2000 forum. </div>
<div>
Located here : <a href="http://www.s2ki.com/s2000/topic/975497-wait-that-isnt-an-f20c/">http://www.s2ki.com/s2000/topic/975497-wait-that-isnt-an-f20c/</a></div>
<div>
<br /></div>
<div>
Thanks for checking the project out :)</div>
Juan Ehringerhttp://www.blogger.com/profile/13103228343094439116noreply@blogger.com1tag:blogger.com,1999:blog-6035647390124489062.post-14965500453734791782012-07-01T18:13:00.003-07:002012-07-01T18:13:19.535-07:00Differential SwapHey everyone<br />
Unfortunately, since I don't update this as often as I wanted to, a bunch of information and pictures have gathered up but still need to be organized. To start sifting through all the data, I decided to tackle an aspect of the car I want to discuss and illustrate what I did and how I did it.<br />
<br />
In this post, I will be concentrating on upgrading my drive train.<br />
<br />
The stock S2000 differential is infamous for being weak and fragile. Even with the stock ~200Hp engine, the car has the capability of destroying its differential if you're having a bad day. Upgrading to a turbo system nearly guarantees eminent failure of the differential.<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="http://sphotos.xx.fbcdn.net/hphotos-ash4/482060_503506529664729_2119784513_n.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" src="http://sphotos.xx.fbcdn.net/hphotos-ash4/482060_503506529664729_2119784513_n.jpg" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Stock S2000 Differential</td></tr>
</tbody></table>
<br />
Differentials are responsible for equally dividing the power delivered by the motor, to the two rear wheels (for a rear wheel drive car).<br />
Generally, a transmission, a clutch, a torque converter, or all three, are sufficient in protecting a car's differential setup. As it just so happens, once the electric car conversion is complete, I will have none of those.<br />
<br />
In addition to lacking substantial buffers prior to the differential, the two electric motor's are capable of producing 700+ horsepower, and 1500ft/lb's of torque under certain conditions. Specifications like these make stock s2000 differentials shudder in their sleep.<br />
<br />
Consequently, since I was adding gratuitous amounts of power to the car, the differential needed to go.<br />
A little research on the topic wasn't very hard, and I found out I had 3 options<br />
<br />
1. Send my stock differential to be cryogenically treated by Puddy mod himself<br />
2. Purchase an R32 Skyline differential<br />
3. Purchase an 8.8" Ford Differential<br />
<br />
I chose the third option.<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="http://sphotos.xx.fbcdn.net/hphotos-ash4/488078_503507049664677_1907951220_n.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="211" src="http://sphotos.xx.fbcdn.net/hphotos-ash4/488078_503507049664677_1907951220_n.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">S2000 Differential Vs 8.8" differential with explorer cap</td></tr>
</tbody></table>
<br />
Option 1 was a little too expensive for my tastes. Puddymod does amazing work, however I couldn't bring myself to pay the $2000+ for the work. Not to mention, even after I had the differential beefed up, I would have to find a way to adapt it to support Dana 1350 drive line components. However, the obvious advantage would be that I would be able to remove the differential, and put it back in with little to no trouble. This would have saved a lot of time, but its ok.<br />
<br />
Option 2 was also rather expensive. A used R32 differential goes for ~$400 and are much more difficult to find than Ford 8.8". Another disadvantage would be that the gearing (rack & pinion gears) aren't easy to find. Lastly, the differential would have to be modified to fit the s2000, however (evidently) the axle flanges are compatible with the stock s2000 axles.<br />
<br />
Option 3 was the winner. The Ford 8.8" independent differential was the perfect match for the s2000. Numerous reasons contributed to the choice. Gearing is abundant for the differential, the differential itself is practically indestructible, 1350 pinion flanges are easy to come by, and it is cheap! It just so happened that I was able to pick one up off craigslist for $75 about 10 minutes away. I really lucked out on that one.<br />
However, there are some drawbacks to the differential. One major set back is that the axles are completely different, and had to be custom made for my car. Additionally, it requires custom mounting, and once installation began I realized that a major problem existed in the inability to install the axles without tearing down the entire rear end.<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="http://sphotos.xx.fbcdn.net/hphotos-snc7/292414_503506822998033_1126078785_n.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="http://sphotos.xx.fbcdn.net/hphotos-snc7/292414_503506822998033_1126078785_n.jpg" width="240" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">The (nearly) final product</td></tr>
</tbody></table>
In order for the 8.8" differential to fit, I needed to figure out how to adapt it to honda's existing differential mounting points. In order to simplify the process, I chose to reuse as much of the mounting hardware as possible. To do this, I ordered a Ford explorer differential cover, which greatly simplified the process of bolting the stock support arm to the new differential. With the differential back plate installed, I began fabricating.<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="http://sphotos.xx.fbcdn.net/hphotos-ash3/528086_503507112998004_1911085897_n.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="http://sphotos.xx.fbcdn.net/hphotos-ash3/528086_503507112998004_1911085897_n.jpg" width="240" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Differential sans-rear cover</td></tr>
</tbody></table>
Using Autocad inventor, and Cambam, I created a simple drawing that I exported to G-code, and ran on my router. The router cut into a 1/4" aluminum plate which I had mounted on its table. I decided to get artsy with my work...<br />
<br />
Here is the completed plate, once cut<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="http://sphotos.xx.fbcdn.net/hphotos-snc7/575358_503506966331352_479007364_n.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="193" src="http://sphotos.xx.fbcdn.net/hphotos-snc7/575358_503506966331352_479007364_n.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">todo completo</td></tr>
</tbody></table>
<br />
I ended up drilling the remaining holes on my drill press, since alignment of the differential was rather difficult. Ideally the differential would have been rectangular, with the pinion flange in the center of one end, and the mounts symmetrically placed on another end. However, the ford 8.8" is the least symmetrical piece of hardware in the entire car. Everything is lobside, uneven, and arbitrarily placed.<br />
<br />
Eventually I got the plate drilled, and the stock mounting arm bolted onto it.<br />
I mounted it in the car, and proceeded to make the front mounts out of some 1/8" steel. This was my first time welding anything, so I practiced a little before hand and dove right in.<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="http://sphotos.xx.fbcdn.net/hphotos-ash4/391443_503511289664253_797676330_n.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="http://sphotos.xx.fbcdn.net/hphotos-ash4/391443_503511289664253_797676330_n.jpg" width="240" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Front mounts (notice minimal clearance)</td></tr>
</tbody></table>
<span style="background-color: white;"><br /></span><br />
<span style="background-color: white;">Measurements were taken for the axles, and the data collected was sent to the Drive Shaft Shop, who promptly delivered some high quality custom axles to my door, big shout out to them!</span><br />
<span style="background-color: white;"><br /></span><br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="http://sphotos.xx.fbcdn.net/hphotos-ash3/582203_503513162997399_1078929084_n.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="http://sphotos.xx.fbcdn.net/hphotos-ash3/582203_503513162997399_1078929084_n.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Custom DSS axles</td></tr>
</tbody></table>
<span style="background-color: white;"><br /></span><br />
When it came time to sell the stock s2000 differential, I was contacted by a man named Ben Herne by email who was interested in my differential. Rather than giving me the full asking price, he offered to trade me an 8.8" limited slip differential, professional installation, and some cash for the differential. After looking up the name, it didn't take long to stumble upon his company, Puddymod racing. His work is revered as some of the best work in the industry. He builds the strongest stock s2000 differentials that have become parts of hundreds of cars.<br />
<br />
I took a trip down to Bradenton Florida to have the LSD installed, and it turned out great! Can't wait to see how it works with the car.<br />
<br />
After removing the differential, I decided that it was mounted too low in the chassis and was susceptible to touching the ground when going up large curbs etc. So, I chose to move it up about 2". I modified my 1/8" mounts, but ended up having to throw them out because I overlooked something.<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="http://sphotos.xx.fbcdn.net/hphotos-ash4/382376_503506616331387_979564662_n.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="http://sphotos.xx.fbcdn.net/hphotos-ash4/382376_503506616331387_979564662_n.jpg" width="240" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">A rather provocative view of the pinion flange </td></tr>
</tbody></table>
<br />
The pinion flange for a 1350 setup is huge, far larger than the stock s2000 flange. The diameter of the flange almost overlaps the s2000's differential mounts. With the previously designed front differential mounts, the pinion flange had about 2 mm of clearance between the mounts. To increase the distance between the flange and mounts, I had to re-do the design. Rather than going out and up, I had to go straight up, and out.<br />
<br />
A day or two later, I had completed the new mounts, and painted them.<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="http://sphotos.xx.fbcdn.net/hphotos-snc7/376502_503506752998040_514438049_n.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="206" src="http://sphotos.xx.fbcdn.net/hphotos-snc7/376502_503506752998040_514438049_n.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">New Vs old</td></tr>
</tbody></table>
<br />
I reinserted the differential, and made sure it did not rub or anything. Everything checked out well!<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="http://sphotos.xx.fbcdn.net/hphotos-ash4/250917_503506682998047_583703576_n.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="http://sphotos.xx.fbcdn.net/hphotos-ash4/250917_503506682998047_583703576_n.jpg" width="240" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">New mount</td></tr>
</tbody></table>
<div class="separator" style="clear: both; text-align: center;">
<br /></div>
<span style="background-color: white;">The last step was to install the stock axles. Another obstacle appeared here; the wheel hubs needed to be removed in order to install the axles. </span><br />
Some hours pass, the axles are installed, and the wheels are back on.<br />
I took some additional time to take out the torque wrench and ensure all my bolts were correctly torqued. I don't want my axle flying off on the highway!<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="http://sphotos.xx.fbcdn.net/hphotos-snc6/165962_503506506331398_1474444543_n.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="http://sphotos.xx.fbcdn.net/hphotos-snc6/165962_503506506331398_1474444543_n.jpg" width="267" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Buttoned up :--)</td></tr>
</tbody></table>
<br />
Since the rear end is completed, I went ahead and reconnected the brake lines, ESC sensors, and hand brake lines that I removed when I uninstalled the rear sub frame to remove the gas tank.<br />
Dropped the car, pushed it, and the pinion flange rotates! Success!<br />
<br />
<br />
<br />Juan Ehringerhttp://www.blogger.com/profile/13103228343094439116noreply@blogger.com0tag:blogger.com,1999:blog-6035647390124489062.post-59208839316706896032012-03-26T16:05:00.003-07:002012-03-26T16:08:05.271-07:00Battery Pack design<span style="background-color: #b6d7a8; font-family: inherit;">Anyone who has followed my build has seen my previous battery plans. Initially, I had anticipated using 10Ah Headway cells. Then I switched to the blue 8Ah cells, since they yielded a lower internal resistance meaning less losses to heat and inefficiencies. Then, I switched to 8Ah cells with an even lower resistance, red 'high power cells'. </span><br />
<div><span style="background-color: #b6d7a8; font-family: inherit;">The game plan was to mate 972 of these cells together, 9p/108s, for a nominal voltage of 345ish and 2000A bursts. </span></div><div><div><span style="background-color: #b6d7a8; font-family: inherit;">I was almost certain the headways were the route I was going to take, however I decided against it in favor of some of the highly acclaimed A123 20Ah pouches. </span></div></div><div><span style="background-color: #b6d7a8; font-family: inherit;"><br />
</span></div><div><span style="background-color: #b6d7a8; font-family: inherit;">Alright, why? Because the cells are pretty awesome. Although their origins are unknown, they still boast some pretty impressive specifications. </span></div><div><span style="background-color: #b6d7a8; font-family: inherit;"><br />
</span></div><div><span style="background-color: #b6d7a8; font-family: inherit;">To get the same performance out of this battery pack, I will a 4s/416s setup, for 343v nominal, and 80Ah capable of 2000A bursts. </span></div><div><span style="background-color: #b6d7a8; font-family: inherit;"><br />
</span></div><div><span style="background-color: #b6d7a8; font-family: inherit;">Not only that, but the headway pack would weight about double what the A123 pack should weigh.</span></div><div><span style="background-color: #b6d7a8; font-family: inherit;"><br />
</span></div><div><span style="background-color: #b6d7a8; font-family: inherit;">The only drawback to the A123 cells is their inability to be put into a pack easily. I originally designed a rather primitive pack, consisting of bus bars separating the cells, and the entire pack would be compressed via a threaded rod that would go through the cells. </span></div><div><span style="background-color: #b6d7a8; font-family: inherit;"><br />
</span></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMZY4_1kj3WXQnuULOjeavwumN_3Nie-k9-KTjJytbE_RR44ERMbel3cw6oIVGe66FLejDc3IxORFjjzn0F1LI6j7CCOqgerc5jDwc7WtLvGhGaSAK9MmieRhkmyz2yJvyXn0BAJc3GVh6/s1600/A123+PACK+proto+1.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span style="background-color: #b6d7a8; color: black; font-family: inherit;"><img border="0" height="236" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhMZY4_1kj3WXQnuULOjeavwumN_3Nie-k9-KTjJytbE_RR44ERMbel3cw6oIVGe66FLejDc3IxORFjjzn0F1LI6j7CCOqgerc5jDwc7WtLvGhGaSAK9MmieRhkmyz2yJvyXn0BAJc3GVh6/s320/A123+PACK+proto+1.jpg" width="320" /></span></a></div><div><span style="background-color: #b6d7a8; font-family: inherit;"><br />
</span></div><div><span style="background-color: #b6d7a8; font-family: inherit;">While this design would work, I had two issues;</span></div><div><span style="background-color: #b6d7a8; font-family: inherit;">1. The threaded rod would have to be some sort of nylon or ceramic. The nylon rod would stretch under heat, and the ceramic rod would be fragile.</span></div><div><span style="background-color: #b6d7a8; font-family: inherit;">2. The cost of the copper needed for the bus bars would be ridiculous. I calculated about $700 worth, using bars of 1/4" and 3/8" copper.</span></div><div><span style="background-color: #b6d7a8; font-family: inherit;"><br />
</span></div><div><span style="background-color: #b6d7a8; font-family: inherit;">With that in mind, I went about designing another pack. <span style="line-height: 18px;">In order to combat the expensive copper necessary for the first pack, I needed to design a pack that didn't rely on the cells connecting directly to each other, since that would call for thick copper to space the cells. I had always wanted to do something along the lines of the white zombie's pack, having the tabs bend over a copper bus bar, and then another bus bar being clamped down on these tabs. However, this wasn't practical using 4 cells in parallel. After a little finicking with my A123 test cells, I figured I would cheat, and treat two 20ah cells as one 40ah cell. Now I need 2 parallel (which is 4 cells), which would allow me to use the clamping system.</span><span style="line-height: 18px;"> 4 cells would need 8 slots, and I dont think the cell's tabs farthest from the central copper mounting bars would reach.</span></span></div><div><span style="line-height: 18px;"><span style="background-color: #b6d7a8; font-family: inherit;"><br />
</span></span></div><div><span style="line-height: 18px;"><span style="background-color: #b6d7a8; font-family: inherit;">A couple of minutes in CAD got me this </span></span></div><div><span style="line-height: 18px;"><span style="background-color: #b6d7a8; font-family: inherit;"><br />
</span></span></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdu5ZN8xcX0MrOJfu7gSBZLDrqflWaVE8Yht7Q4Sn6jt-toMzzAPM4Vv4K8aQulYrnjiO0C5wqnXSiyv0B2WChXhB5ORtAuGcqUjo2Wav2VqAor8RMtdsoZFk78TslkD2JWBGPTEDuFAiH/s1600/Final+Proto+1.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span style="background-color: #b6d7a8; color: black; font-family: inherit;"><img border="0" height="244" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgdu5ZN8xcX0MrOJfu7gSBZLDrqflWaVE8Yht7Q4Sn6jt-toMzzAPM4Vv4K8aQulYrnjiO0C5wqnXSiyv0B2WChXhB5ORtAuGcqUjo2Wav2VqAor8RMtdsoZFk78TslkD2JWBGPTEDuFAiH/s320/Final+Proto+1.jpg" width="320" /></span></a></div><div><span style="font-family: inherit;"><span style="background-color: #b6d7a8; line-height: 18px;"><br />
</span></span></div><div><span style="background-color: #b6d7a8; font-family: inherit;"><span style="line-height: 18px;">Simply by changing the design, I was able to reduce the cost of the copper significantly. </span><span style="line-height: 18px;">With the new clamping design, I can use 1/8 copper bus bars, with more surface area. The total copper price for all eight packs will be around $223 (according to onlinemetals.com).</span><span style="line-height: 18px;"> </span><span style="line-height: 18px;"><br />
</span></span></div><div><span style="font-family: inherit;"><span style="background-color: #b6d7a8; line-height: 18px;"><br />
</span></span></div><div><span style="font-family: inherit;"><span style="background-color: #b6d7a8; line-height: 18px;">I then optimized the design, and entered some more accurate dimensions for the final battery pack file. </span></span></div><div><span style="font-family: inherit;"><span style="background-color: #b6d7a8; line-height: 18px;">I decided to make the pack with a 1/4" polycarbonate top, so that I can see the batteries. It also isn't much more expensive than other plastics. I wanted to use 3/8", however the cell tabs would not be long enough to go through the plastic slots, and attach to the copper bus bars. </span></span></div><div><span style="background-color: #b6d7a8; font-family: inherit;"><span style="line-height: 18px;">The sides of the box will be 3/8"</span><span style="line-height: 18px;"> on the short sides and 1/4" on the longer sides. There will be half an inch of space between the cells and the edges, so there is some room for error. Foam padding will be placed in these gaps to secure the cells. </span></span></div><div><span style="font-family: inherit;"><span style="background-color: #b6d7a8; line-height: 18px;"><br />
</span></span></div><div><span style="font-family: inherit;"><span style="background-color: #b6d7a8; line-height: 18px;">Here are some pictures of the final design</span></span></div><div><span style="font-family: inherit;"><span style="background-color: #b6d7a8; line-height: 18px;"><br />
</span></span></div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbAXz-WHj-1M4VIWno77U-bLk9N3_Mu-8lz0TzN-DFmJ82LbPqn6Vce58yq_57hzBHTD5HvFL04DHwLSSMz0vzl76MolUnL67djyDTe1n7mK2kN_5jXVzMUdlbFh8uaTjW6QQ0dK8hw705/s1600/wireframe.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span style="background-color: #b6d7a8; color: black; font-family: inherit;"><img border="0" height="235" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhbAXz-WHj-1M4VIWno77U-bLk9N3_Mu-8lz0TzN-DFmJ82LbPqn6Vce58yq_57hzBHTD5HvFL04DHwLSSMz0vzl76MolUnL67djyDTe1n7mK2kN_5jXVzMUdlbFh8uaTjW6QQ0dK8hw705/s320/wireframe.jpg" width="320" /></span></a></div><span style="background-color: #b6d7a8;"><br />
</span><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqWQvr72XJxzmnmp2ukhchd0Z7PndBRiLoZwN8-T0LVrS5dC24fW61f5Wgq68HOaSn_Zkr83WfG3qpe0JomAAlKijc4FyJ0C5rgKJ-a2AHGd-E925YD5Rt93FJPf8tYct8IDuNru5ZizT9/s1600/Extruded.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span style="background-color: #b6d7a8; color: black; font-family: inherit;"><img border="0" height="223" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgqWQvr72XJxzmnmp2ukhchd0Z7PndBRiLoZwN8-T0LVrS5dC24fW61f5Wgq68HOaSn_Zkr83WfG3qpe0JomAAlKijc4FyJ0C5rgKJ-a2AHGd-E925YD5Rt93FJPf8tYct8IDuNru5ZizT9/s320/Extruded.jpg" width="320" /></span></a></div><span style="background-color: #b6d7a8;"><br />
</span><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnjjOMIeglP2YnlsII7vQhGjs2WpWqy-yeF9_DpqPuOXx15CgpDnrf3KmS6seu0DEt1dRAZ5OHJp4oEB2XUClJrbhTpFtzCpu3oRe81W_lQRM_7vKGDVVNVyfaNGhKb_Vs6dmUr6PGeKxW/s1600/Rendered.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><span style="background-color: #b6d7a8; color: black; font-family: inherit;"><img border="0" height="212" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgnjjOMIeglP2YnlsII7vQhGjs2WpWqy-yeF9_DpqPuOXx15CgpDnrf3KmS6seu0DEt1dRAZ5OHJp4oEB2XUClJrbhTpFtzCpu3oRe81W_lQRM_7vKGDVVNVyfaNGhKb_Vs6dmUr6PGeKxW/s320/Rendered.jpg" width="320" /></span></a></div><div><span style="font-family: inherit;"><span style="background-color: #b6d7a8; line-height: 18px;"><br />
</span></span></div><div><span style="font-family: inherit;"><span style="background-color: #b6d7a8; line-height: 18px;">I still need to add some copper bus bars to the pack, but I just needed the box dimensions for now. </span></span></div><div><span style="font-family: inherit;"><span style="background-color: #b6d7a8; line-height: 18px;">The hole drilled through the center of the copper bars will hold them to the polycarbonate top plate, while two more holes will be drilled on the sides of the same bus bar to secure it to the larger bus bar which will hold 2 groups in series.</span></span></div><div><span style="font-family: inherit;"><span style="background-color: #b6d7a8; line-height: 18px;"><br />
</span></span></div><div><span style="font-family: inherit;"><span style="background-color: #b6d7a8; line-height: 18px;">From there, I contacted a couple of engineering schools around where I live, and found a place to CNC the top plate and the individual sides of the battery box.</span></span></div><div><span style="font-family: inherit;"><span style="background-color: #b6d7a8; line-height: 18px;"><br />
</span></span></div><div><span style="background-color: #b6d7a8; line-height: 18px;">I still have more to update, I will update soon!</span></div>Juan Ehringerhttp://www.blogger.com/profile/13103228343094439116noreply@blogger.com2tag:blogger.com,1999:blog-6035647390124489062.post-32838568945082764622012-03-22T20:28:00.000-07:002012-03-22T20:28:10.208-07:00Working out the final design kinks<div>Long time no update.</div><div>Truth be told, lots of informative and pertinent information regarding the build has been gathered,but I have been much too lazy to type it all up. So I will now dump it onto the internet!</div><div><br />
</div>I am still rather upset at the slow pace at which this conversion is taking place. While I work on the designing the car for countless hours each week, I can't help but feel like I am moving in place. I assume most builds feel similar, but darn. Oh well, with the motors nearly mounted and the battery packs finalized, the so called 'light at the end of the tunnel' can now be seen with a telescope. <div><br />
</div><div>Anyway, here we go.....</div><div><br />
</div><div>Motors:</div><div><br />
</div><div>A serious milestone was passed when I was finally able to order a coupler for the two warp motors. I called probably 300 different businesses, trying to find a reliable and trust worthy solution to coupling the litte red monsters. The solution to all the chaos finally came when I gave up on locating an appropriately rated coupler, and purchased a $20 generic set screw coupling. </div><div><br />
</div><div>It basically is a steel oxide coupler with a 2 1/4" outer diameter, and a 1 1/8" inner diameter, with a keyway. Not much to it, but it is only rated to 2500 RPM and 100 Ft Lbs of torque. My car will be hitting a 5500 Rpm redline, and have a max potential torque of 1500 Ft Lbs of torque. Quite a disparity between the two specifications, however I am hoping for the best. In the worst case scenario, the coupler explodes while on the freeway, sending shrapnel everywhere and destroying anything in its path. But what are the chances of that *knock on wood*??</div><div><br />
</div><div>With the coupler out of the way, I had a U channel made out of a 1/8" piece of aluminum. I then had two 1/4" arms welded to this channel, which would be situated in the original motor mount locations. The large U channel came out surprisingly cheap, ringing in at $60. Seeing how cheap a large piece of custom bended metal was, I returned back to the shop to have the 2 aluminum arms welded onto the channel. I was then hit hard with a $350 bill. I have no idea how two small arms took $350 of welding, regardless I was kinda upset and purchased a new tig machine.</div><div><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh5ZF90aqvfLeetQyuQpIktsJ6Nyrdj4No_kbOFNVd2uIOMgM9pfmX3h1J8UNGe8-81l5UbKxsQe-DaQRoVfOyJ6_wG__JZBh_QMgrxYGM5RguU_Z0uPioo7qbRikap5MiTu7blepBnrooI/s1600/IMG_1230.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh5ZF90aqvfLeetQyuQpIktsJ6Nyrdj4No_kbOFNVd2uIOMgM9pfmX3h1J8UNGe8-81l5UbKxsQe-DaQRoVfOyJ6_wG__JZBh_QMgrxYGM5RguU_Z0uPioo7qbRikap5MiTu7blepBnrooI/s320/IMG_1230.JPG" width="240" /></a></div><div><br />
</div><div>I went ahead and spent a little extra to purchase a better 'starter' model. </div><div>With the new machine, I carried on finishing up the motor mounting. Unfortunately, I soon discovered that having a nice welder doesn't ensure good welds.</div><div><br />
</div><div>My first project was to weld up some steel brackets to hold my differential in place. I used stick welding to do this, and was surprised by how straight forward and forgiving of a process it was. Needless to say, I welded up the two brackets, and had the differential mounted back into the car in a day or two. (more on this soon)</div><div><br />
</div><div>All my good luck was forsaken later that week when I began aluminum welding. I practiced on some scrap aluminum with relatively good results, however when the time came to weld two of the motor end place onto the U channel, my welding suffered severely. I could not get the base metal to melt, the filler rod would always bead up, I would constantly spoil my tungsten. It was simply a bad start. </div><div><br />
I never really got any better at it, and as a result the welds look horrible. But I suppose it works.<br />
I feel as though my failure was due to the large shape of the U channel, which acted as a giant heatsink wicking away all the heat I was producing. </div><div><br />
</div><div>Regardless, I was able to horribly weld the front most motor holding place, and I simply tack welded the back plate, so now I can drop it off at a welding shop and have them actually do it professionally. Two more plates will be bolted to the U channel, but will be removable to allow for the movement of the warp motors. </div><div><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmWuuTX7dUHKIccLnwPZvP8Fb25Smdslo6FeFJWXKOhZnSmVjDHmc0DSGLd4vVz4SOi1avqxfNYMhcZFvUh_CQnumEuTVFOVwv661FrS-I8c2E47CGTP1K_NMn5_TnyIIWWZaXUUKIEXrg/s1600/IMG_1324.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEgmWuuTX7dUHKIccLnwPZvP8Fb25Smdslo6FeFJWXKOhZnSmVjDHmc0DSGLd4vVz4SOi1avqxfNYMhcZFvUh_CQnumEuTVFOVwv661FrS-I8c2E47CGTP1K_NMn5_TnyIIWWZaXUUKIEXrg/s320/IMG_1324.JPG" width="240" /></a></div><br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEipiQtdhgri4tsup0WH4VK7myNu2fwqcvHKL5Nx3WcXB_PM5Ca8-GH7EITwM8B-5hbmPrZuHluXgl92EllVWkwFKW65b_563x18ammaDSv-qNnBtGr3BJiiV6_TVlJ024acuxfXHHdnejSn/s1600/IMG_1325.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEipiQtdhgri4tsup0WH4VK7myNu2fwqcvHKL5Nx3WcXB_PM5Ca8-GH7EITwM8B-5hbmPrZuHluXgl92EllVWkwFKW65b_563x18ammaDSv-qNnBtGr3BJiiV6_TVlJ024acuxfXHHdnejSn/s320/IMG_1325.JPG" width="320" /></a></div><div><br />
</div><div>With the motor positions finalized, I will be able to put the motors in the car and get an accurate measurement for a driveshaft length. </div><div>I hope to have the driveshaft ordered by tomorrow, since my custom driveshafts are ready to ship! (more about this soon also).</div><div><br />
</div><div><br />
</div><div><br />
</div><div><br />
</div>Juan Ehringerhttp://www.blogger.com/profile/13103228343094439116noreply@blogger.com0tag:blogger.com,1999:blog-6035647390124489062.post-9633357482393507932012-01-08T12:08:00.000-08:002012-01-08T12:10:25.729-08:00Getting things into motionIn the world of physics, it is universally understood that a large amount of energy is needed to overcome the inertia and the friction an object is experiencing, in order to bring it into motion. After an initial velocity has been reached, less energy is necessary to maintain a constant velocity.<br />
<br />
I hope the same holds true for my project. I have recently realized that I have had the S2000 in my possession for six months, and have not accomplished much more than planning and disassembly. After sitting down for a short period, and putting things into perspective, I realized that I have to accelerate my work. Summer is approaching quickly, and I need my car by then.<br />
<br />
That said, I have begun to order parts, and design more in my free time. I hope that once I begin receiving parts, my work will go along quicker and I will be more prolific on the project throughout the week. Once I get the gist of the process, I pray the project will be completed in about six months.<br />
<br />
/ End rant /<br />
<br />
Now, to the interesting part!<br />
Since the last update, I have completed a couple of small things.<br />
After discovering the immense amount of space the soft top occupies, I went directly to removing it.<br />
<br />
Originally, I had anticipated purchasing a hard top for the car, but after driving it while it had a gas engine in it, with the top down, I found my decision to use a hardtop or soft top fluctuating.<br />
Replacing the soft top is expensive, but a hardtop is even more expensive.<br />
<br />
After removing the soft top (which is extremely heavy), and finding an immense space available for batteries, I made a final choice to purchase a hardtop.<br />
<br />
Since an OEM hardtop would have a cost rivaling that of the entire car, I will most likely go with a cheaper, more aerodynamic approach. A knock-off Spoon 2 piece hard top from VIS will most likely be the winner in this hardtop showdown. Not only will it make the car appear more stealthy ( :D ), but it will also increase aerodynamics, while still allowing for the space previously occupied by the soft top to be used for battery placement.<br />
<div style="text-align: center;"><br />
</div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_4WedJ-8QG635TW1JeN3tXnUIGKpooZr7Yw11_nBxdMBu_bP_Q8qdll9Ta2RS0cd5JKCZ00aDEWJHOOfESk8KJG0OpFbkSOWbSa0Q08HhP-znLTEzAXqY36Gp6raJEjVVF76qpRqNtzsI/s1600/VIS+spoon.gif" imageanchor="1" style="margin-left: auto; margin-right: auto; text-align: center;"><img border="0" height="230" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh_4WedJ-8QG635TW1JeN3tXnUIGKpooZr7Yw11_nBxdMBu_bP_Q8qdll9Ta2RS0cd5JKCZ00aDEWJHOOfESk8KJG0OpFbkSOWbSa0Q08HhP-znLTEzAXqY36Gp6raJEjVVF76qpRqNtzsI/s320/VIS+spoon.gif" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">VIS Spoon Replica Top</td></tr>
</tbody></table><br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2Kmt5J7FDYXwJRXMMDuPDQwYF9kpzuOt_CUAYmaQHYV66SZcCB7_-ajuNcFR0eqxy54O15ExGdxYMnAnNMfdvi8Y9Pn8HoPu0R2ex6YK6_HhNnkqITecSPqFXb0BSHz4sDYy1FzBHDQI0/s1600/s2000+final.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="180" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh2Kmt5J7FDYXwJRXMMDuPDQwYF9kpzuOt_CUAYmaQHYV66SZcCB7_-ajuNcFR0eqxy54O15ExGdxYMnAnNMfdvi8Y9Pn8HoPu0R2ex6YK6_HhNnkqITecSPqFXb0BSHz4sDYy1FzBHDQI0/s320/s2000+final.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="font-size: 13px;">What I hope the car will look like with the top installed</td></tr>
</tbody></table><br />
After much deliberation, and studying, I have decided to shy away from using an under/overdrive. Cost, extra work, and extra complications involved while using a transmission have been the primary deciders for me.<br />
<br />
Instead, I will use a direct drive approach, coupling the motors directly to the rear differential. With this decision, it will be necessary for the weak stock s2000 differential to be replaced with a 8.8" Ford pumpkin.<br />
A day or two after posting on craigslist proved successful, and I picked up a 8.8" with 3.73 gears for $75 from a man half an hour away from my home. Work has already begun on adapting the large chunk to fit into the s2000.<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0qqU9auS8MXeSiMHz0qZsNur9cN6TjkGHZjwJuKOHs2ITKllpzz0KBE8_9ca2j2jfWlyoTz-0KGLjLs3AOhWuuvY_VpQu2s8AvQB-ZnGgyTcr3zwIE5DMe5SDyNlV3NT6YDaeqGIZZ7lu/s1600/IMG_0655.JPG" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEh0qqU9auS8MXeSiMHz0qZsNur9cN6TjkGHZjwJuKOHs2ITKllpzz0KBE8_9ca2j2jfWlyoTz-0KGLjLs3AOhWuuvY_VpQu2s8AvQB-ZnGgyTcr3zwIE5DMe5SDyNlV3NT6YDaeqGIZZ7lu/s320/IMG_0655.JPG" width="240" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">The 8.8 with cover removed</td></tr>
</tbody></table><br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqQOF9oqz-zIvpUxFZ17erOKMaFEAeg33-ZEe7fSQs-7wOchTrOE_IdoQjx7UjweuheL3YygEMCBMYAgq8aoJoBJ5njLPSGpEtHeKAKbztAybiKSRtYaE-iFUgq9vykpwAkTXNnHasKgTo/s1600/rpm+vs+speed.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto; text-align: center;"><img border="0" height="162" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEhqQOF9oqz-zIvpUxFZ17erOKMaFEAeg33-ZEe7fSQs-7wOchTrOE_IdoQjx7UjweuheL3YygEMCBMYAgq8aoJoBJ5njLPSGpEtHeKAKbztAybiKSRtYaE-iFUgq9vykpwAkTXNnHasKgTo/s320/rpm+vs+speed.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Some calculations showing RPM vs. MPH</td></tr>
</tbody></table><br />
A major effort to design a suitable motor mounting plate has been made over the last two weeks. I have done an innumerable amount of research on the topic, until I stumbled upon the John Wayland's dual 8" warfield design from late 2000.<br />
<div><br />
</div><div>John employed a simple U-channel design, constructed out of a single piece of aluminum to hold his motors in place. </div><div><br />
</div><div>I seized the opportunity, and designed a common plate for my dual 9" motors, taking ideas from John, and introducing some of my own. </div><div><br />
</div><div>While I have not completed the final rough draft, I have already a metal worker assisting me, and should have the basic U channel out of the shop by next Wednesday. </div><div><br />
</div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEguTJsTM7wNqronEb7Vh7bQGl5hQIrbrK69vdJu6kGE4Nv5EMyfVWQj7Y5y94yMWQ4nqXqfKc-LUCt98XgtlhGznALumj_aieOHPqW8tyFQ2dLoUHOE7Gt4baP2NxmcrpVj8-4GY0qlFjvA/s1600/Mount.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto; text-align: center;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEguTJsTM7wNqronEb7Vh7bQGl5hQIrbrK69vdJu6kGE4Nv5EMyfVWQj7Y5y94yMWQ4nqXqfKc-LUCt98XgtlhGznALumj_aieOHPqW8tyFQ2dLoUHOE7Gt4baP2NxmcrpVj8-4GY0qlFjvA/s1600/Mount.jpg" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">John's common plate</td></tr>
</tbody></table><div><br />
</div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjSBP9d553MjTPbFsQkTQ6WTQKSF_OK1y9fiXyUXjBX0NWzhpVFnMIlZKNU16160NKCU-iVqaO6W3epJqGfbjgwXHIvhuysRc34xr4g2yF6_VqAjycMSKZpjVtD1MaU-tigEIHQMIlcOiGY/s1600/mount2.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto; text-align: center;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjSBP9d553MjTPbFsQkTQ6WTQKSF_OK1y9fiXyUXjBX0NWzhpVFnMIlZKNU16160NKCU-iVqaO6W3epJqGfbjgwXHIvhuysRc34xr4g2yF6_VqAjycMSKZpjVtD1MaU-tigEIHQMIlcOiGY/s1600/mount2.jpg" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Another view</td></tr>
</tbody></table><div></div><div><br />
</div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNnvM1H_jTeoj0JKBEz7LkEcD3-dvnXF8ZxS4ZXc9D1sMqqnFVTY4adXh4N18C28G7oYREh1BS_rFC8xK9oXIkbd6Clv8mFkoa0rQ5sNc2uknmqYOWUAf6m7MJv-XsBrSjalKfqyCZnaeo/s1600/mount+3.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto; text-align: center;"><img border="0" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNnvM1H_jTeoj0JKBEz7LkEcD3-dvnXF8ZxS4ZXc9D1sMqqnFVTY4adXh4N18C28G7oYREh1BS_rFC8xK9oXIkbd6Clv8mFkoa0rQ5sNc2uknmqYOWUAf6m7MJv-XsBrSjalKfqyCZnaeo/s1600/mount+3.jpg" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Another view, without motors</td></tr>
</tbody></table><br />
<div></div><div><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMBrO8lGbtbX2aAKx029FFyUvEFRmJA7FebBavMb_INLG-ae2SGIIQCwx5hb72g9fIAkPKexooUb2D_4E9QU6OnzM0bcGrpFwAYfKFUDxUia_gRvV-J-gNC4TwYEcEE8p93rO9NAkY19Dy/s1600/Motor+mount.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto; text-align: center;"><img border="0" height="248" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiMBrO8lGbtbX2aAKx029FFyUvEFRmJA7FebBavMb_INLG-ae2SGIIQCwx5hb72g9fIAkPKexooUb2D_4E9QU6OnzM0bcGrpFwAYfKFUDxUia_gRvV-J-gNC4TwYEcEE8p93rO9NAkY19Dy/s320/Motor+mount.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">My first draft of a common plate</td></tr>
</tbody></table><br />
I also purchased a single Kilovac Bubba contactor, its a lot bigger than it looks!<br />
<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNNAqjcG_-FMMW998riYcyct5wA2ZIpitwPYkeZ-OyFqtiIcZllRE4sIXiLJ5kZ4s1PGU3HMe8va4P_IdKSP2oyIJ75R9gDVyH4nPeR3bYIwx2ThxYr1ipsDuIC8VeYcufDmZ7KwkY5Zce/s1600/IMG_0656.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEiNNAqjcG_-FMMW998riYcyct5wA2ZIpitwPYkeZ-OyFqtiIcZllRE4sIXiLJ5kZ4s1PGU3HMe8va4P_IdKSP2oyIJ75R9gDVyH4nPeR3bYIwx2ThxYr1ipsDuIC8VeYcufDmZ7KwkY5Zce/s320/IMG_0656.JPG" width="240" /></a></div><br />
<div class="separator" style="clear: both; text-align: center;"><br />
</div> More updates soon!<br />
<div class="separator" style="clear: both; text-align: center;"><br />
</div><br />
<div class="separator" style="clear: both; text-align: center;"><br />
</div><br />
<div class="separator" style="clear: both; text-align: center;"><br />
</div><br />
<div class="separator" style="clear: both; text-align: center;"><br />
</div><br />
<div class="separator" style="clear: both; text-align: center;"><br />
</div><div class="separator" style="clear: both; text-align: center;"><br />
</div><br />
<br />
</div>Juan Ehringerhttp://www.blogger.com/profile/13103228343094439116noreply@blogger.com0tag:blogger.com,1999:blog-6035647390124489062.post-48198215840652215092011-12-22T12:48:00.000-08:002011-12-22T12:48:21.619-08:00Motor Removed<div class="separator" style="clear: both; text-align: center;"><br />
</div>Well I finally got the motor (including tranny) completely out.<br />
<br />
Took a while since I wasn't really working very often on it, maybe once a weekend.<br />
I was rather complacent once the engines were removed, it was something I needed to get out of the way, but haven't bothered. I'll let the pictures do the talking.<br />
<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/409607_347743201907730_100000161580553_1633841_1146622454_n.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/409607_347743201907730_100000161580553_1633841_1146622454_n.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Finally got the wheels off thanks to my new impact</td></tr>
</tbody></table><br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc7/395395_347743308574386_100000161580553_1633842_1040734881_n.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="http://a7.sphotos.ak.fbcdn.net/hphotos-ak-snc7/395395_347743308574386_100000161580553_1633842_1040734881_n.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">The transmission had to be removed from beneath the car</td></tr>
</tbody></table><br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/381903_347743371907713_100000161580553_1633843_47690671_n.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/381903_347743371907713_100000161580553_1633843_47690671_n.jpg" width="240" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Lifting...</td></tr>
</tbody></table><br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc7/s720x720/402362_347743441907706_100000161580553_1633844_2051173024_n.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="320" src="http://a4.sphotos.ak.fbcdn.net/hphotos-ak-snc7/s720x720/402362_347743441907706_100000161580553_1633844_2051173024_n.jpg" width="240" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Out!</td></tr>
</tbody></table><table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/381437_347743508574366_100000161580553_1633845_1567229174_n.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="240" src="http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/381437_347743508574366_100000161580553_1633845_1567229174_n.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Glory shot</td></tr>
</tbody></table><div class="separator" style="clear: both; text-align: center;"><br />
</div><div class="separator" style="clear: both; text-align: center;"><br />
</div>In other news, I managed to pick up a sponsorship from Headway Batteries for their new high power cells.<br />
The discharge curve for these cells is even better than their predecessor, not to mention they are now a fire red.<br />
I expect some really nice discharge from these cells. Hopefully they last a couple of cell cycles too. Only time will tell.<br />
<br />
<table align="center" cellpadding="0" cellspacing="0" class="tr-caption-container" style="margin-left: auto; margin-right: auto; text-align: center;"><tbody>
<tr><td style="text-align: center;"><a href="http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/385959_337852639563453_100000161580553_1599623_736786880_n.jpg" imageanchor="1" style="margin-left: auto; margin-right: auto;"><img border="0" height="202" src="http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/385959_337852639563453_100000161580553_1599623_736786880_n.jpg" width="320" /></a></td></tr>
<tr><td class="tr-caption" style="text-align: center;">Discharge curve for the new cells</td></tr>
</tbody></table><br />
Since I have picked up the motors, I have been designing a 3d model to aid in constructing a common plate for them. Its interesting learning a new program, but it gets tiring having to learn multiple programs just to meet a single goal.<br />
<br />
<div class="separator" style="clear: both; text-align: center;"><a href="http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/390132_347763321905718_100000161580553_1633941_1982031240_n.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="215" src="http://a4.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/390132_347763321905718_100000161580553_1633941_1982031240_n.jpg" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
</div><div class="separator" style="clear: both; text-align: center;">Im sure I will have some more news in the days to come, stay tuned!</div>Juan Ehringerhttp://www.blogger.com/profile/13103228343094439116noreply@blogger.com0tag:blogger.com,1999:blog-6035647390124489062.post-1729535903334633402011-12-22T12:17:00.000-08:002011-12-22T12:17:01.741-08:00Los Motores ~About two weeks ago I traveled to Rebirth Auto in Tampa to meet up with Steve, and pick up my motors.<div>Everything went smoothly, received a guided tour of the company, and got some free stickers and shirts! I can definitely recommend them to anyone building an electric car. Best of all, both motors successfully fit in the back of the Benz.</div><div><br />
</div><div>Here are the pictures!!</div><div><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc7/390288_334615346553849_100000161580553_1589861_384640521_n.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="http://a6.sphotos.ak.fbcdn.net/hphotos-ak-snc7/390288_334615346553849_100000161580553_1589861_384640521_n.jpg" width="320" /></a></div><div><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/392715_334647349883982_100000161580553_1590091_377379895_n.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="http://a1.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/392715_334647349883982_100000161580553_1590091_377379895_n.jpg" width="320" /></a></div><div><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/378869_334647436550640_100000161580553_1590093_1465334924_n.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="http://a5.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/378869_334647436550640_100000161580553_1590093_1465334924_n.jpg" width="320" /></a></div><div><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/384814_334648006550583_100000161580553_1590097_207476460_n.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/s720x720/384814_334648006550583_100000161580553_1590097_207476460_n.jpg" width="320" /></a></div><div><br />
</div>Juan Ehringerhttp://www.blogger.com/profile/13103228343094439116noreply@blogger.com0tag:blogger.com,1999:blog-6035647390124489062.post-35315600537893794392011-11-28T15:35:00.001-08:002011-11-28T15:44:09.857-08:00A Small Update<span class="Apple-style-span" style="font-family: inherit;">Back again!<br />
<br />
Well this build is going slower than I had hoped :/<br />
My father insists that we order one component at a time, since he isn't in any rush, but I was really hoping to finish the vehicle by the end of the year. Oh well, better safe than sorry.<br />
<br />
Approximately 6 weeks ago I ordered the motors from Rebirth Auto, hoping they would arrive within the week, however they still haven't arrived which is upsetting but understandable. I ordered a transwarp 9 and a warp 9, which I intend on coupling together. I don't fully know how I am going to couple them together, but I hope for it to be rather straight forward. </span><br />
<div><span class="Apple-style-span" style="font-family: inherit;"><br />
Once the motors come in, I will post pictures of them for you guys to see. I also plan on picking up some small little tid bits while I am down in Tampa picking up the motors. Wire, connectors, contactors...<br />
</span></div><div class="separator" style="clear: both; text-align: center;"><span class="Apple-style-span" style="font-family: inherit; margin-left: 1em; margin-right: 1em;">As soon as the motors arrive, I plan on ordering a 3 or 2 speed gear vendors transmission to finish off the drive train. I know that Ron (Team haiyan) and John Metric (DC plasma) are using the gear vendors, so I know I am purchasing a tranny that has some proof in the pudding. <br />
<br />
<br />
<br />
<br />
<br />
<img border="0" height="230" src="http://bowlertransmissions.com/images/Items/3D0420C_10092008084406_medium.jpg" width="400" /><br />
The transmission!!<br />
<br />
Since my last update, I have disassembled the car to the bare engine and transmission. I Have yet been able to remove the drive shaft, which is the only thing stopping me from extracting the drive train. Its STUCK on there, since the dumb honda engineers decided to use 6mm, galvanized steel hex nuts to hold the driveshaft in place. So of course they stripped out, and now have to be cut off. <br />
<br />
<br />
<br />
<br />
<br />
<img border="0" height="240" src="http://a8.sphotos.ak.fbcdn.net/hphotos-ak-ash4/304188_302825903066127_100000161580553_1466530_1320674088_n.jpg" width="320" /><br />
<br />
<br />
<br />
<br />
<img border="0" height="240" src="http://a2.sphotos.ak.fbcdn.net/hphotos-ak-ash4/298559_302825963066121_100000161580553_1466531_644230844_n.jpg" width="320" /><br />
These pictures were taken a while ago, since then many more components have been removed <br />
<br />
<br />
<img border="0" src="http://a6.sphotos.ak.fbcdn.net/hphotos-ak-ash4/296860_302825689732815_100000161580553_1466527_1424592543_n.jpg" /><br />
My Zilla 2k EHV also arrived too! The first thing I noticed was how heavy it was. It came nicely wrapped in a cardboard cocoon, ensuring it would get to me safely. Manzanita Micro made the process very quick and easy, something I applaud them for. <br />
<br />
<br />
<img border="0" src="http://a3.sphotos.ak.fbcdn.net/hphotos-ak-snc7/316287_302825843066133_100000161580553_1466529_246110432_n.jpg" /><br />
The hair ball has so many inputs, so many possibilities <img border="0" src="http://www.diyelectriccar.com/forums/images/smilies/biggrin.gif" /><br />
<br />
Hopefully, next weekend I will be down in Tampa picking up my motors and a bunch of other components. Once I get the motors installed in the car, the batteries will be ordered, something I cant wait for.<br />
<br />
-JE</span></div><div></div>Juan Ehringerhttp://www.blogger.com/profile/13103228343094439116noreply@blogger.com0tag:blogger.com,1999:blog-6035647390124489062.post-60391864469247518182011-10-02T19:28:00.000-07:002011-10-02T19:28:54.819-07:00UpdateAlthough I had announced earlier last month that a final parts list had been compiled for the car, plans have changed.<br />
<div><br />
The idea of running a single Warp 11HV was ruled out after I contacted George of Netgain Motors, and he advised me to stay away if I were to use direct drive. From what I have heard, direct drive delivers no significant advantages over a transmission, especially when using a 50 pound 2 speed tranny. In order to achieve the highest efficiency possible, I will have to use a transmission.</div><div><br />
</div><div>Another factor that helped sway me from the idea of using the 11HV was the implementation of a smaller armature coil, relative to the regular non-HV 11. This was imperative in order to achieve higher RPM's. Unfortunately, with every reaction there is an equal or opposite reaction, and in this case it results in less torque from 0 rpm. </div><div><br />
</div><div>Based on these findings, I have decided to run a more 'John Metric' style of car, utilizing dual 9" motors, with a small transmission at the end. Hopefully this will supply me with enough power to zoom from 0-60 in less than 4 seconds. My only concern with running dual motors is the increased length, which I hope will fit in the transmission tunnel underneath the car. </div><div><br />
</div><div>On another note, Netgain is planning to release new revisions to their motor line ups, which means that I may have to wait a little longer than anticipated to receive my motors. </div><div><div class="separator" style="clear: both; text-align: -webkit-auto;"><br />
</div>This weekend I began disassembling my S2000, which was a momentous checkpoint in my build. At first it was easy, removing small things like the air box and hood, however as time progressed, it became more tedious. Nothing hard work and perseverance wont solve! So far, I have removed both radiators, the air conditioning system, air box, battery, exhaust, headers,and the engine cooling system.<br />
<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjND7WSf6izCjLFivBDVM2kjgRFTbFqXf3rx9rCLJI8Yvx3U7wVErvHaWuCoJx00JVAYsgFnyotbIKkkXW_Ao6VohaTlPKJkD-7vcYEJy48ok7GuKJfjBNm7lNVd3UhmOQUOqrIO6U-rOw1/s1600/DSCF5006.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjND7WSf6izCjLFivBDVM2kjgRFTbFqXf3rx9rCLJI8Yvx3U7wVErvHaWuCoJx00JVAYsgFnyotbIKkkXW_Ao6VohaTlPKJkD-7vcYEJy48ok7GuKJfjBNm7lNVd3UhmOQUOqrIO6U-rOw1/s320/DSCF5006.JPG" width="320" /></a></div><br />
<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjyAs6zAaak1qNPsXFBLd8cLZ8xzB1S_L0E6lkvGPP77qCIHedhJFA28QsdirskwwUjG0ksq9Ld5PLcusBZ3ePvC1uit0YkzJcSQ7g5cTiKrpDao18eR0IPZDggnH4ER1Tpd50N6xcozB9X/s1600/DSCF5005.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjyAs6zAaak1qNPsXFBLd8cLZ8xzB1S_L0E6lkvGPP77qCIHedhJFA28QsdirskwwUjG0ksq9Ld5PLcusBZ3ePvC1uit0YkzJcSQ7g5cTiKrpDao18eR0IPZDggnH4ER1Tpd50N6xcozB9X/s320/DSCF5005.JPG" width="320" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
</div><br />
The job was going smoothly, until it came time to remove the wheels, at which point I was stumped to find out there was a unique lock nut on each rim.<br />
<br />
<div class="separator" style="clear: both; text-align: center;"><a href="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjY3JeDpf9fT505vmRzu1wvpVP0qFeritNVMv_DxUC1JG5Gkumd_Y2axl-O7b8NnYhGu-sqJ2YlV7k8Z5mymEwBMQc7SQ_892fARJB_g2GCom6BZmk21DdK6MsRX4KWR7Fc6JHUWB0Fjuwa/s1600/DSCF5007.JPG" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="240" src="https://blogger.googleusercontent.com/img/b/R29vZ2xl/AVvXsEjY3JeDpf9fT505vmRzu1wvpVP0qFeritNVMv_DxUC1JG5Gkumd_Y2axl-O7b8NnYhGu-sqJ2YlV7k8Z5mymEwBMQc7SQ_892fARJB_g2GCom6BZmk21DdK6MsRX4KWR7Fc6JHUWB0Fjuwa/s320/DSCF5007.JPG" width="320" /></a></div><br />
Only Honda will have this key, so come the business week, I will venture out to purchase a graciously overprice piece of steel the size of a big toe. I am not in much of a hurry to disassemble the car, since I know that there will be unbearably long lead times for my parts, which I hope to soon place an order for.<br />
<div class="separator" style="clear: both; text-align: -webkit-auto;"><br />
</div>More to come next week.</div>Juan Ehringerhttp://www.blogger.com/profile/13103228343094439116noreply@blogger.com0tag:blogger.com,1999:blog-6035647390124489062.post-35013494391244265622011-08-30T16:18:00.000-07:002011-08-30T16:18:22.913-07:00Final Parts ListFinally some news worth publishing!<br />
<br />
The electric car is coming along, slowly but surely! After a couple months of planning, hundreds of emails, innumerable calculator buttons pressed, and buckets of tears and blood, the car has finally recieved its final parts list. Here she is:<br />
<br />
<br />
<ol><li>Zilla 2000 EHV -Ordered</li>
<li>Warp 11" HV, custom modified by Dennis Berube, owner of the 'Current Eliminator'</li>
<li>1008 Headway 8ah 38120P battery cells</li>
</ol><div>I know you must be in disbelief, how can picking 3 parts take two months? Well, it took a while to figure out which motor to get, and who to modify it for me. That said, the single most time consuming choice was undisputedly the battery pack. Not to mention, figuring out how to couple the engine to the transmission in direct drive. </div><div><br />
</div><div style="text-align: center;"><a href="http://i1003.photobucket.com/albums/af153/CroDriver/DSC07420.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="http://i1003.photobucket.com/albums/af153/CroDriver/DSC07420.jpg" width="240" /></a></div><div class="separator" style="clear: both; text-align: center;"></div><div class="separator" style="clear: both; text-align: center;">Crodriver battery pack</div><div class="separator" style="clear: both; text-align: center;"><br />
</div><div>The pack will be run in 112 series / 9 parallel. This will allow for 375.2v, and 2000 amps at 28c. </div><div>Theoretically, this pack would be able to release, 751Kw, which in gear head terms, is 1008 Hp. Unfortunately, we live in an imperfect world, and using a simple formula, it is easy to uncover the peak Hp after accounting for 'inefficiencies'. The battery pack should be able to release 551 Kw, aka 740 Hp. Not too shabby! To make good news a little worse, we will only be able to get about 500 hp out of the poor motor, which is running nearly double its recommended current. As each individual cell weighs 300g, the battery pack as a whole should weight 665 lbs. Painful, I know, however there isnt much I can do. The good news is that I expect an average battery usage of 250ish WhM^-1, so with almost 26kwh's of energy I should be able to travel 105ish miles on a charge!</div><div><br />
</div><div>I originally wanted to use a 16ah headway pack, however the impedance on each of the individual cells was too high (>8 milli-ohms). Then, I wanted to get A123 batteries from a so called 'reseller' of their batteries. In the end, the batteries would cost about $27k. Simply too much for me to afford. </div><div><br />
</div><div>The good news is, according to similar cars, the s2000 should be able to zip down the street quickly, hitting 60mph in about 2.3 +/- 0.5 seconds from a stand still. Some may say I'm being optimistic, but my excitement inundates all outside errors. </div><div><br />
</div><div>I am basing my battery packs construction on crodrivers battery pack, using plexiglass or 'sipas' to hold the assembly together. The only problem I am sure to encounter is in regard to the car's minuscule size and free space. The battery pack is going to contain 1009 cells, each of which have a size of 138cm^3.</div><div>So theoretically, I would need a cube with sides 52cm long to store all that juice, but once again, nothing ever works out the easy way (a reoccurring theme). I know for a fact, that I will need to separate batteries into the trunk and engine compartment. I do plan on installing a recessed area for the batteries in the trunk, however I don't really know what will happen in the engine compartment. </div><div><br />
</div><div class="separator" style="clear: both; text-align: center;"><a href="http://i1003.photobucket.com/albums/af153/CroDriver/DSC07619.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="http://i1003.photobucket.com/albums/af153/CroDriver/DSC07619.jpg" width="240" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
</div><div class="separator" style="clear: both; text-align: center;">Crodriver completed battery pack (10ah Headway, 108s/8p)</div><div><br />
</div><div>Until next time!</div><div><br />
</div><div><br />
</div><div><br />
</div>Juan Ehringerhttp://www.blogger.com/profile/13103228343094439116noreply@blogger.com0tag:blogger.com,1999:blog-6035647390124489062.post-77825076719512974082011-06-09T19:37:00.000-07:002011-06-09T19:37:46.039-07:00The Host<span class="Apple-style-span" style="font-family: Verdana, sans-serif;">When I brought up the idea of an electric car to my father, who would be the patron of this project, he didn't initially like the idea of a super fast motor, in a small, lightweight car. I explained how I was in need of a car that could handle a big motor, and was light weight, and he counter argued me by laying down some criteria for the car;</span><br />
<br />
<ul><li><span class="Apple-style-span" style="font-family: Verdana, sans-serif;">It had to be more recent model, newer than 2000</span></li>
<li><span class="Apple-style-span" style="font-family: Verdana, sans-serif;">It had to have air bags</span></li>
<li><span class="Apple-style-span" style="font-family: Verdana, sans-serif;">It had to be around $6k</span></li>
<li><span class="Apple-style-span" style="font-family: Verdana, sans-serif;">It had to be in Florida, within driving distance</span></li>
</ul><div><span class="Apple-style-span" style="font-family: Verdana, sans-serif;">Not only did I have to meet my fathers expectations, but I also had to find a car that was lightweight as it would be more efficient than a heavier car. Truthfully, I knew I could reach this criteria, however I didn't know if I wanted to. Originally, I looked into salvaging a Honda CRX since they only weigh about 1700 lbs. However, after lots of consideration of cars, I ultimately decided that I didn't want to convert a cheap, second hand car just because I didn't originally have enough money to invest into a better platform. Long story short, after multiple suggestions, and failures I had a firm decision on converting a Honda S2000 Convertible. Why? Simply because it met all my fathers criteria. Diving deeper into my decision; The cars manual transmission, RWD, light weight, and god looks sealed the deal for me. </span></div><div><span class="Apple-style-span" style="font-family: Verdana, sans-serif;"><br />
</span></div><div><span class="Apple-style-span" style="font-family: Verdana, sans-serif;"><span class="Apple-style-span" style="color: #1c2837; line-height: 19px;">After a lot of searching, I came along this little gem on craigslist for 8k. I low balled the guy offering 6k, he counter offered me 6300, and I agreed! It was in Orlando, and I live about an hour away, so it was really close! Anyway, I ended up paying the guy $6500 to get a tow truck deliver it since he hasn't registered it for 4 years to evade the taxes. It has a clean title, and 80k miles on it, but it needs a new top, and there are miscellaneous small parts that need repairing (the top is ripped, one headlight doesn't work, an AC vent is missing, and the clutch is slipping). I figured since Im going to be working on it anyway, those problems will be rather trivial. Without further explanation, here is a picture of me in my driveway right after she was delivered!</span></span></div><div class="separator" style="clear: both; text-align: center;"><a href="http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/250596_232914706723914_100000161580553_1162458_6929594_n.jpg" imageanchor="1" style="margin-left: 1em; margin-right: 1em;"><img border="0" height="320" src="http://a1.sphotos.ak.fbcdn.net/hphotos-ak-snc6/250596_232914706723914_100000161580553_1162458_6929594_n.jpg" width="240" /></a></div><div class="separator" style="clear: both; text-align: center;"><br />
</div><div class="separator" style="clear: both; text-align: center;">The tear down will begin soon, just sit tight!</div><div><span class="Apple-style-span" style="font-family: Verdana, sans-serif;"><span class="Apple-style-span" style="color: #1c2837; line-height: 19px;"><br />
</span></span></div>Juan Ehringerhttp://www.blogger.com/profile/13103228343094439116noreply@blogger.com0tag:blogger.com,1999:blog-6035647390124489062.post-68571789715304534262011-05-30T07:14:00.000-07:002011-06-09T19:38:09.319-07:00Introduction<span class="Apple-style-span" style="font-family: Verdana, sans-serif;">If you're reading this blog, odds are that you are either a personal friend of mine, or someone who is interested in electric car conversions. Either way, I hope the blog is both informative and motivational to you and whoever you may share it with. This blog will follow my progress in the conversion of my 2002 Honda S2000, and although it may be unachievable, I am anticipating a completion date of about 6 months. As time passes through the next 2 weeks - month, I will address multiple aspects and components of the electric car, ranging from the motor choice, to the BMS (Battery Managment System). It will surely be a tough, and interesting (to say the least) journey from internal combustion gas guzzler, to speedy electric sports car, but I am itching to get started. </span><br />
<span class="Apple-style-span" style="font-family: Verdana, sans-serif;"><br />
</span><br />
<span class="Apple-style-span" style="font-family: Verdana, sans-serif;">Anyway, about me; I'll try to be relatively terse here. I am a 16 year old attending Spruce Creek High School, enrolled in the IB program. I don't have very much of a background with cars, since this electric car will be my first. I've never changed oil, or replaced a tire; the most I've ever done is fill the water for the windshield wipers. That said, I am fairly practical by nature, and if I devote myself to something, I can generally complete it within a couple of months. My main motivation in life is in the pursuit of scientific knowledge, and at school, I have more friends than I can count on 2 hands, that are encouraging and interested in the project. </span><br />
<span class="Apple-style-span" style="font-family: Verdana, sans-serif;"><br />
</span><br />
<span class="Apple-style-span" style="font-family: Verdana, sans-serif;">One last thing I will address in this post; what is the point of creating an electric car? </span><br />
<span class="Apple-style-span" style="font-family: Verdana, sans-serif;">1. Efficiency: <span class="Apple-style-span" style="-webkit-border-horizontal-spacing: 1px; -webkit-border-vertical-spacing: 1px;">The average car uses about 20% of the potential energy of the fuel in useful motion while wasting the other energy as heat, noise and pollution. Electric cars use upwards of 80% of their 'fuel', a percentage which can be increased relatively easily as most of its losses are electrical. <b>So in essence an ICE car is a heater with the side effect that it can move people from A to B.</b></span></span><br />
<span class="Apple-style-span" style="-webkit-border-horizontal-spacing: 1px; -webkit-border-vertical-spacing: 1px;"><b><span class="Apple-style-span" style="font-family: Verdana, sans-serif;"><br />
</span></b></span><br />
<span class="Apple-style-span" style="-webkit-border-horizontal-spacing: 1px; -webkit-border-vertical-spacing: 1px;"><span class="Apple-style-span" style="font-family: Verdana, sans-serif;"><b>2. </b>Economical: This is a no brainer, America imports more oil than any other country. Not only that, but a lot of people don't realize how subsidized it is. The gas station up the street is currently selling premium for $4.05 a gallon. However, in Italy, where it is subsidized but not as much, the price of a US gallon, is $6.00. </span></span><br />
<span class="Apple-style-span" style="-webkit-border-horizontal-spacing: 1px; -webkit-border-vertical-spacing: 1px;"><span class="Apple-style-span" style="font-family: Verdana, sans-serif;"><br />
</span></span><br />
<span class="Apple-style-span" style="-webkit-border-horizontal-spacing: 1px; -webkit-border-vertical-spacing: 1px;"><span class="Apple-style-span" style="font-family: Verdana, sans-serif;">3. Enviromental: Most people are informed of global warming, and how our cars are inundating our world in CO2. Electric cars emit no hydrocarbons, and now toxic gases whatsoever. </span></span><br />
<span class="Apple-style-span" style="-webkit-border-horizontal-spacing: 1px; -webkit-border-vertical-spacing: 1px;"><span class="Apple-style-span" style="font-family: Verdana, sans-serif;"><br />
</span></span><br />
<span class="Apple-style-span" style="-webkit-border-horizontal-spacing: 1px; -webkit-border-vertical-spacing: 1px;"><span class="Apple-style-span" style="font-family: Verdana, sans-serif;">And finally, for the people who say, "well, the electricity for electric cars comes from huge complexes that are still killing our earth." </span></span><br />
<span class="Apple-style-span" style="font-family: Verdana, sans-serif;"><span class="Apple-style-span" style="-webkit-border-horizontal-spacing: 1px; -webkit-border-vertical-spacing: 1px;">Well, you guys are right, to a point. Even if all cars become electric, we will need a source of energy, but that doesn't mean that it has to be from harmful and inefficient fuels. We have solar farms, water turbines, and wind turbines, that could, in the near future, produce enough energy for electric cars. Also, coal and nuclear power, although they have negative externalities, are cleaner, cheaper, and domestic compared to foreign oil. Gas cars only use about 25% of the energy in their fuel, and electric cars are capable of using 99.999% of their energy, something gas engines cannot achieve. </span></span><br />
<span class="Apple-style-span" style="font-family: Verdana, sans-serif;"><span class="Apple-style-span" style="-webkit-border-horizontal-spacing: 1px; -webkit-border-vertical-spacing: 1px;">One last aspect is that, electric cars </span><b style="-webkit-border-horizontal-spacing: 1px; -webkit-border-vertical-spacing: 1px;">are</b><span class="Apple-style-span" style="-webkit-border-horizontal-spacing: 1px; -webkit-border-vertical-spacing: 1px;"> the way of the future. Why? Because all the types of green and upcoming energy sources will be incompatible with gas engines. Internal combustion engines need a combustible liquid to function, and petrol basically has the best combustibility of anything else. If we were to change to Hydrogen Fuel cells, everyone would have buy a new car, since you can't just put a hydrogen fuel cell in a gas engine. On the other hand, if we all invested in electric cars, the hydrogen fuel could be converted to electricity at our local power plants, and then used when we plug our cars into the wall outlet. </span></span><br />
<span class="Apple-style-span" style="font-family: Verdana, sans-serif;"><span class="Apple-style-span" style="-webkit-border-horizontal-spacing: 1px; -webkit-border-vertical-spacing: 1px;"><br />
</span></span><br />
<span class="Apple-style-span" style="font-family: Verdana, sans-serif;"><span class="Apple-style-span" style="-webkit-border-horizontal-spacing: 1px; -webkit-border-vertical-spacing: 1px;">I'm not saying that the gas car you are driving sucks, and that you need to get rid of it, but rather that there are better ways of running cars, that I, and many others, hope will catch on soon. </span></span>Juan Ehringerhttp://www.blogger.com/profile/13103228343094439116noreply@blogger.com0