33 Machine electric 818e build- Sold! Headed to China!

[ehansen007]

HEADLINES:

http://green.autoblog.com/2014/04/28/factory-five-racing-818-ev-battery-powered-electric/


http://gas2.org/2014/04/28/video-electric-factory-five-818-makes-much-sense/

As most of you probably assumed by my input and comments I AM actually building an 818. :confused: Why not post the progress you ask? Good question. Here's the answer: It was determined that we would keep this on the skunk-works side of things until we pulled the curtain at SEMA. Well, that recently fell through and because there are others out there doing electric (the amazing Bob from Cincy comes to mind) I figured what's the point? Time to share. ;)

This is such an amazing candidate for electric that it has caused a major stir in the EV community. I had made my decision back in January that this would be the way I would go due to my interest in building outside the box as well as my background in racing RC cars. And it's amazing the similarities this new full scale technology has with it's smaller counterparts. For this project I have teamed with EV West (http://www.evwest.com) who have already proven themselves to be incredible engineers as well as consummate professionals with an incredible track record in the EV racing circle.

So here it is for those who are interested:

Powertrain:
HPEVS AC35x2 with Dual Curtis 144V motor controllers with water cooled chill plates Power Graph (http://hpevs.com/Site/images/torque-curves/ac-35x2/144%20volt/imperial/ac-35X2%20144v%20imperial%20peak%20data.pdf)
2002 Subaru 5sp manual with sport clutch and lightened flywheel
EV West Water Jetted adapter plate and custom coupler
50 Cell- CALB LiFe 3.2V 100Ah- 160V (144V - Sag)
ELCON- PFC 5000 Charger (http://www.evwest.com/catalog/product_info.php?cPath=12&products_id=97&osCsid=u457mafj3qvj055rkul9i5df67)
DC to DC converter
Custom aluminum battery boxes
EVnetics Hall Effect throttle
Bosch Charging Station (http://www.evwest.com/catalog/product_info.php?cPath=39&products_id=166&osCsid=u457mafj3qvj055rkul9i5df67)
Sparco Assetto Gara Wheels 18x8 -20lb (chosen for price point and light weight)
Hankook Ventus v112k 215/40/18- 20lb (same)

Expected Performance - We'll find out!
Expected Range - ~60 Miles

http://i897.photobucket.com/albums/ac177/ehansen007/Powerchart_zps20f1c5a1.jpg (http://s897.photobucket.com/user/ehansen007/media/Powerchart_zps20f1c5a1.jpg.html)

[ehansen007]

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/P1060036_zpseba31b46.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/P1060036_zpseba31b46.jpg.html)
The shipped package we all know and love. Stewart Shipping will not be visiting here again I can assure you. Many problems in scheduling meant I had to have the Wookie meet them at the house while I was out of town on vacation for 3 days. Thanks Hodgie!



http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/P1060045_zps9dfe7a44.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/P1060045_zps9dfe7a44.jpg.html)
Mine all mine.


http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/P1060047_zps570df6ed.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/P1060047_zps570df6ed.jpg.html)
Most Parts all prepped and ready to go. Replaced all bearings as well. I'm not a fan of having a beat up car in the garage so I sourced parts from various sources including a guy that was parting out a shell for $500.

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/P1060048_zpsb0e9af0f.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/P1060048_zpsb0e9af0f.jpg.html)

[ehansen007]

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Naked!


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Someone's ready at 7yrs old. he'll never get the keys...cause there won't be any! :)


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The ones I call when I need to lift the chassis and other miscellaneous heavy lifting. Give them a beer and they'll do anything.


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Some other friends drop by to start the build.


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What's wrong with this picture?

[ehansen007]

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Nothing like keeping it in the family. He's helping cut off a bolt here.


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After a hard days work it's time for a juice box and some thin mints (I saved on box just for the occasion)


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new rotors and pads from BrakeMotiv on ebay. $150. They worked great on the hot rod and they look even better. They won't rust either.

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/P1060080_zps1a92e086.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/P1060080_zps1a92e086.jpg.html)
Roller is done and waiting for wheels

[ehansen007]

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/P1060087_zpsdf089364.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/P1060087_zpsdf089364.jpg.html)
Time to get started on the battery placement. This Graham Cracker box is the same size as the CALB100.

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/P1060088_zps23c363ee.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/P1060088_zps23c363ee.jpg.html)
Fitting behind the firewall. Perfect!

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/IMG_2415_zps0c59b502.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/IMG_2415_zps0c59b502.jpg.html)
Now the nose. One battery box will go here for sure but those shifter cables may just clear it.

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/P1060093_zpsdffffa31.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/P1060093_zpsdffffa31.jpg.html)
Transmission being fitted

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/IMG_2414_zps743f82b6.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/IMG_2414_zps743f82b6.jpg.html)
Wood blocks for mockup only :p

[ehansen007]

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/IMG_2419_zpseacd13d2.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/IMG_2419_zpseacd13d2.jpg.html)
I got the carbon package with the kit so I thought this wheel would be a good match.

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/P1060098_zpsa174b934.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/P1060098_zpsa174b934.jpg.html)
I was amazed this worked. And worked well!

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/IMG_2421_zpsda6f3962.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/IMG_2421_zpsda6f3962.jpg.html)l
Rear diff removed

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I recently acquired this very important piece of equipment. As LongIslandWRX says "A well stocked beverage fridge is the key to any successful project."

[ehansen007]

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/P1060104_zps88777870.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/P1060104_zps88777870.jpg.html)
The guys from EV West come in big time here. They delivered these sweet wheels from Tire Rack so we could get them on the trailer and headed down to their shop.

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/P1060106_zps7cf07a76.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/P1060106_zps7cf07a76.jpg.html)
Moon buggy?

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Loading up

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/IMG_2450_zps357b4ddc.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/IMG_2450_zps357b4ddc.jpg.html)
Picked up the motor and controllers from HPEVs (http://www.hpevs.com) and brought them down to the shop.

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/IMG_2456_zps2ec9d698.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/IMG_2456_zps2ec9d698.jpg.html)
Mocking up battery boxes for placement

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Batteries are in. Guys please don't ask me how much this is all costing. It will only remind me. :)

[ehansen007]

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This is Michael Bream- engineer extraordinaire. He's using vinyl to mock up the adapter plate for the motor and putting it in SolidWorks

VIDEO
http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/th_IMG_2443_zpsbbff073d.jpg (http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/IMG_2443_zpsbbff073d.mp4)

Speaking of solidworks, Michael had the entire frame in solidworks in one evening so we could determine battery placement. Please don't ask me for the file as it's not mine to give. However, it doesn't appear to be that hard if you have solidworks?

VIDEO
http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/th_IMG_2440_zps5b1dfa07.jpg (http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/IMG_2440_zps5b1dfa07.mp4)

Here's a quick view of the shop. That BMW is amazing. Be sure to check out their page on it.

[ehansen007]

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Adapter plate back from Water jetting. We decided to go this route for time since we were still planning on SEMA.

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/IMG_2513_zps3c55ebfe.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/IMG_2513_zps3c55ebfe.jpg.html)
Checking motor position for front motor mount design.

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Yup, that bar is gone! The uniqueness of this motor has caused us to remove the cross bar from that section of the frame.

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/IMG_2516_zpse36657fe.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/IMG_2516_zpse36657fe.jpg.html)
Body mockup. This was fun as Mark Stackler and Jeff Miller were in town so we had a few beers and started putting things on like a bad Revel Snap tite model! Gorilla tape worked better than clamps!

[ehansen007]

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/IMG_2541_zps4f96f5f1.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/IMG_2541_zps4f96f5f1.jpg.html)
Front motor mount base created.

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/P1060113_zps26c78079.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/P1060113_zps26c78079.jpg.html)
Motor mount welded in as well as retro-fitted supports (re-used the bar I cut out..talk about recycling!)
You can also see where I cut the old mounts off, then welded in a rail and tabs for the rear battery boxes. CG should be pretty good on this.

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/IMG_2545_zps872f32b7.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/IMG_2545_zps872f32b7.jpg.html)
Unfortunately, we had to cut this to get the front box in. I made a removable bar to go in it's place. It's a bummer for sure but I don't think it will affect the structure too much.

[ehansen007]

Ok, done adding posts and pics for now. Thanks if some were waiting to comment. And thanks to those who knew about this project and were helping to keep quiet. Finally I'd like throw a big thanks out to Eric Kriss and Bob Grunewald for enduring and answering my questions on Electric Vehicle technology in the beginning. Their encouragement and expertise have been awesome and I couldn't have gotten here without them. If anyone has any questions, just let me know.

e

[Mechie3]

So how much...

I mean...


Can I have the....

errr...


Very nice! It isn't hard to make a frame in SW, just tedious and time consuming to get it right. Very cool!

Does that wheel come in a D/flat bottom variety? I'm looking to possibly replace my stocker with a smaller one.

[ehansen007]

Does that wheel come in a D/flat bottom variety? I'm looking to possibly replace my stocker with a smaller one.

no, sorry, the carbon is limited edition and round only. I'm 6-1" and can get in an out easily though with it in. Let me know if you want one! :)

[longislandwrx]

I recently acquired this very important piece of equipment. As LongIslandWRX says "A well stocked beverage fridge is the key to any successful project."


Amazing! I've been looking for one for a while, but haven't font the one I want at the right price. Well done, you just showed up everyone who has ever been on MTV cribs.


Looking forward to watching you press throttle and turn gears into nice smooth circles. :D

[Xusia]

I like that wheel! Like Mechie3, I wish it was a flat bottom. Question about it though: Can you replace the NRG center piece with one from Factory Five (assuming you could get one)?

[ehansen007]

Probably. I think the FFR one is bigger but you could probably make it work.

[Frank818]

Nice motor! Electric with 5sp?

[fateo66]

Honestly I'm surprised that you are using a clutch, for some reason I assumed there wouldn't be a need for one. Do most other electric cars have one too?

[ehansen007]

Well, there are clutchless setups out there however shifting can be tedious. Also, this is the budget way for sure. I could have opted to buy something like a CVT or similar but it would have been thousands not hundreds. With this torque curve I may only be using 2nd, 4th, and 5th. Not sure yet. I think it will be fun and for those who have built them, they say you definitely want gears and not an auto.

[Bob_n_Cincy]

Hey Erik
Looking great. We need to talk.
Bob

[drdracing]

Got my 818R last Fri. very interested in the carbon fiber wheel. Can you let me know cost etc. Thanks, Rick

[RM1SepEx]

That's an $ 7000 battery pack... 50 100AH CALB at around $140 each
About the same $ for the motor and controllers
add chargers, adaptor plate etc...
easily $20,000 in the drivetrain! Should be very powerful and performance should be awesome

[Frank818]

I really don't understand the tranny on an electric motor, it's the first time I hear about more than 2 gears on an electric motor.
Plz explain how this works. tnx

[Erik W. Treves]

looking great!!

[metalmaker12]

Amazing stuff!!! I am impressed

[Xusia]

In regards to a clutch, couldn't you just cut power to the motor? Cutting power to allow for shifts is done in motorcycling all the time (search Google for quickshifters). You could wire a switch to the clutch pedal to simulate a clutch and accomplish this.

[Bob_n_Cincy]

In regards to a clutch, couldn't you just cut power to the motor? Cutting power to allow for shifts is done in motorcycling all the time (search Google for quickshifters). You could wire a switch to the clutch pedal to simulate a clutch and accomplish this.

When you push in the clutch, the transmission synchronizers only have to bring a 2 lb clutch disk to the same speed as the transmission. So engagement is smooth. The clutch also acts as a torque limiter to the transmission. 300-500 ft lbs.

On an EV the motor rotor is 40 to 80 lbs. The synchronizer can't match the motor to the transmission speed. So with no speed match and no torque limiter when the gear engages I suspect there is a few thousand foot lbs torque spike going through the transmission.
I've seen multiple Formula Lightning EV teams blow their transmission on the first lap.
bob

[xatudor]

If I'm not mistaken the graph is mislabelled, as IIRC electric motors make next to maximum torque right from zero rpm, hence why an electric motor when started DOL (switched on with no variable speed drive or current limiter) draws 6 times the rated full load current. Also horsepower is the product of torque and rpm, hence why the horsepower increases linear to the rpm
I am open to correction if I'm wrong.
I think you may want to look at a different final ratio as with maximum torque available from zero I think you may not need second gear also.
I'm looking forward to watching your build log as I enjoyed watching you build your 33.

[frankeeski]

Great progress Erik!

[Xusia]

When you push in the clutch, the transmission synchronizers only have to bring a 2 lb clutch disk to the same speed as the transmission. So engagement is smooth. The clutch also acts as a torque limiter to the transmission. 300-500 ft lbs.

On an EV the motor rotor is 40 to 80 lbs. The synchronizer can't match the motor to the transmission speed. So with no speed match and no torque limiter when the gear engages I suspect there is a few thousand foot lbs torque spike going through the transmission.
I've seen multiple Formula Lightning EV teams blow their transmission on the first lap.
bob

Well that explains why people don't do that. I also had not considered the benefit of using the clutch as a torque limiter. With so much torque available so quickly, it makes sense.

[RM1SepEx]

I really don't understand the tranny on an electric motor, it's the first time I hear about more than 2 gears on an electric motor.
Plz explain how this works. tnx

basic old trade off

if you want max eff you minimize gear train to minimize losses. Many EVs use very high voltage to get high RPM, if you do this you can get away with less or even a single gear. Lower RPM motors need add'l gears just like a gas engine... the torque max at min rpm of the electric means the regular gas engine 1st is too low and not needed. most early EV setups with low voltage motors used trannys. The adv of a clutch have been documented above. big torque with little mass = huge shock loads = very bad juju. also lower amp loads = less heat related losses at a given speed that requires higher gearing. Faster accel requires lower gearing... trans gives you both.

[Frank818]

Tnx Dan. :)

[Jay Mann]

I wondered why you have been so quiet on the forums. A very cool project!!

[jkrueger]

Very cool. Keep us updated. I can't wait to see it finished.

JC

[Frank818]

So this motor gives 180wtq from 0 to 5000rpm?

Any idea of the overall 818 weight?

[ehansen007]

as for weight we did this exercise with a 36 pack of batteries xand single AC 50 motor and it came out to almost a wash. I imagine this will be around 2000+ a little.

[VD2021]

Man......My EE is spilling out of me right now. I'm am so glad you are sharing this. Gotta love the torque curve (or should I say LINE).

[ehansen007]

A little Thursday morning fun

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/image_zps37d928b7.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/image_zps37d928b7.jpg.html)

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/image_zpsa4751b96.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/image_zpsa4751b96.jpg.html)
Off to powdercoat!!
http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/image_zpsc195f3ea.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/image_zpsc195f3ea.jpg.html)
I'm lucky to have great friends in the neighborhood.

[longislandwrx]

Now that's how you transport a kit!

[ehansen007]

http://i897.photobucket.com/albums/ac177/ehansen007/image8_zps950d15a0.jpeg (http://s897.photobucket.com/user/ehansen007/media/image8_zps950d15a0.jpeg.html)
Back from powdercoat

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Firewall going in

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Roller back in shape for transport

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/image_zpse88d0860.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/image_zpse88d0860.jpg.html)

I used the Evercoat Rubberized undercoating on the firewall.

[ehansen007]

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/image6_zps7e980630.jpeg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/image6_zps7e980630.jpeg.html)
Back down at EV West in San Marcos to begin EV build up.

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/image4_zps31546818.jpeg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/image4_zps31546818.jpeg.html)
Battery boxes built and set in place.

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/image7_zpsb6d13101.jpeg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/image7_zpsb6d13101.jpeg.html)

[RM1SepEx]

I'd remove the tubing used for the center tunnel and run a battery box down the center with those batteries two wide in a nice aluminum box. The tunnel serves no purpose in your build, in our's it only provides a space for the wiring harness and support for the shifter and Ebrake...

[ehansen007]

These batteries are just a bit too tall for that unfortunately and I am using the tunnel for the shifter and ebrake. It would hurt the seat selection as well. What I am considering doing is cutting out the tubing and putting the shifter and ebrake on the floor.

[gwader]

Holy batteries! I've been on the wrong threads.

[Erik W. Treves]

neat!

[skullandbones]

Are you scaling this 818 as you go along to get the desired weight distribution? It looks like you might have some real advantage compared to a conventional engine build.

Thanks, WEK.

[ehansen007]

It's the Batt-mobile. ;).

[Bob_n_Cincy]

It's the Batt-mobile. ;).
You can have Batt-mobile if I can be the Green Lantern


22414

[Silvertop]

It is just plain amazing to me that there is not one but multiple electric 818's being built so early in the 818 program. You guys have cahones!!:D

[Frank818]

Nice glider! :D

[ehansen007]

Are you scaling this 818 as you go along to get the desired weight distribution? It looks like you might have some real advantage compared to a conventional engine build.

Thanks, WEK.
The plan is to move weight around but
We know she's going to be *** heavy. We haven't put her on the scales yet.

[ehansen007]

I'm not sure if anyone noticed but I got the sport konis with my kit in the front and the yellows in the back. Are the reds going to be too stiff? The yellows were very soft in the rear comparatively.

http://i897.photobucket.com/albums/ac177/ehansen007/image9_zps1d2bd498.jpeg (http://s897.photobucket.com/user/ehansen007/media/image9_zps1d2bd498.jpeg.html)
Got my new headlights in. They have the new DRL feature which should be cool.

http://i897.photobucket.com/albums/ac177/ehansen007/1381592552_zps5b0344ec.jpg (http://s897.photobucket.com/user/ehansen007/media/1381592552_zps5b0344ec.jpg.html)
My buddy Matt calls this the "Aerosol Overhaul"

http://i897.photobucket.com/albums/ac177/ehansen007/1381592595_zps3f4f3e1f.jpg (http://s897.photobucket.com/user/ehansen007/media/1381592595_zps3f4f3e1f.jpg.html)
Boxes with the battery bars to hold them down. I'm learning so many new disciplines on this build it's not even funny.

http://i897.photobucket.com/albums/ac177/ehansen007/1381592637_zps0e4acb5b.jpg (http://s897.photobucket.com/user/ehansen007/media/1381592637_zps0e4acb5b.jpg.html)
All done. Now to polish them up so they look nice.

[Mechie3]

That transmission looks amazing!

I like those lights. Is the projector the low beam or high beam? A long term plan of mine is to go aftermarket and do a proper HID retrofit. If I do it now though, and don't modify the stock lights, I might be able to sell them and recoup some value.

[07FIREBLADE]

I believe those are a hid low with halogen high.

[ehansen007]

That's correct.

[longislandwrx]

did you crack the case, pull all the bolts, paint and then paint or just masked them off?

lol

Nice.

[wleehendrick]

Got my new headlights in. They have the new DRL feature which should be cool.


Are those the Spyder Auto piece? I've been eyeing them.

[ehansen007]

did you crack the case, pull all the bolts, paint and then paint or just masked them off?

lol

Nice.

Masked them off. I was originally going to paint the tranny black but changed my mind. Still I like the look of the bolt versus just painting them.

[ehansen007]

Are those the Spyder Auto piece? I've been eyeing them.

I got mine from protuninglab.com but I think they are the same. They were $309 including the HID conversion. Some places advertise cheaper but then charge for the HID upgrade. Make sure you have the option to select the color temp. I picked 6000K which is ICE White (slight blueish hue)

[C.Plavan]

Those are the headlights I bought two months ago (first thing I bought for my 818R). They look great.

[flytosail]

I believe those are a hid low with halogen high.


I am fairly certain you got enough batteries to power them. Great looking build.

What are you looking for as a range number?

[metalmaker12]

Your build is amazing dude!!!!!

[gwader]

Very clean!

[Mechie3]

I believe those are a hid low with halogen high.

So a non projector HID beam?

[ehansen007]

It's a projector. Its the one out the outside not the inside.

Also, after a huge snafu with the brake setup (found out my "donor" was an Impreza) I found a set of GC8 brakes, rotors, hubs, etc on ebay. Started putting some lipstick on that pig as soon as the truck dropped them off. I already have new rotors and pads as these are pretty much gone.

http://i897.photobucket.com/albums/ac177/ehansen007/DSC_0489_zpsdc252979.jpg (http://s897.photobucket.com/user/ehansen007/media/DSC_0489_zpsdc252979.jpg.html)
Shipped these from Canada! Although they've been sitting out for a while and the rotors are gone the rest was in pretty good shape! I think the owner took them off because he thought a bearing had seized but it turns out a broken ABS toner ring was jammed in the works.

http://i897.photobucket.com/albums/ac177/ehansen007/DSC_0472_zpse09db951.jpg (http://s897.photobucket.com/user/ehansen007/media/DSC_0472_zpse09db951.jpg.html)

Turns out the 98 Impreza GC8 (Japanese STI) carried over to the 2002-07 WRX.

http://i897.photobucket.com/albums/ac177/ehansen007/1381850983_zps1a41ea92.jpg (http://s897.photobucket.com/user/ehansen007/media/1381850983_zps1a41ea92.jpg.html)
4 Pistons are better than 2! Should be great stoppers for sure. Not sure if I'm going to highlight the Subaru logo or not. The back doesn't have it.

[Bob_n_Cincy]

Hey Erik
I love those brakes because they are lighter than mine. You will only need them for panic stops as regen will take care of normal stops.
Bob

[gwader]

its not to late for the angle grinder.

[ehansen007]

Hey Erik
I love those brakes because they are lighter than mine. You will only need them for panic stops as regen will take care of normal stops.
Bob


Ha ha. Yeah, the guys at EV West were saying we could have the car running in a week and I was saying that we're not running anything without brakes. They said we'd just turn up the regen to 100%!! Not sure how much regen I will run on this. Pretty exciting really as this is all new territory for me.

[Mechie3]

Those front brakes are the same as the 06/07 WRX brakes except the USDM WRX didn't have the raised Subaru logo, but a sticker.

[ehansen007]

Should I grind it off or pay tribute to the Subaru underpinnings?

[Mechie3]

I'm torn myself. I had mine blasted and powdercoated. Part of me wants to put the subaru stickers back on while part of me wants to put something like "FFR 818" or something else. While I want to pay tribute, I don't at the same time want people thinking it's some new fangled Subaru. Not that I dislike Subaru (my DD is a WRX afterall) but I want the car to be unique and a mystery. lol.

[David Hodgkins]

Should I grind it off or pay tribute to the Subaru underpinnings?

Hmm. Good question. I think I'd leave the Subaru badge.

:)

[Bob_n_Cincy]

Should I grind it off or pay tribute to the Subaru underpinnings?
Your EV is very little Subaru
Go for FFR or HMS

Bob

[wleehendrick]

4 Pistons are better than 2! Should be great stoppers for sure. Not sure if I'm going to highlight the Subaru logo or not. The back doesn't have it.

Grind off the 'SUBARU'!

I'm glad they changed the later WRX 4-pot to a flat face; it made it easy to sand off the logo, repaint with Duplicolor caliper red, and add a special touch:

22573

[fateo66]

Not to mention the added spoke clearance:cool:.

[Frank818]

Nice logo. :)
How did you do it so cleanly?

[wleehendrick]

Nice logo. :)
How did you do it so cleanly?

Thanks, but I can't take credit, I had them printed here:

http://www.vinzdecals.com/createcaliper.html

[David Hodgkins]

OK I take back my last statement. Get the 818 logo!

:)

[ehansen007]

http://i897.photobucket.com/albums/ac177/ehansen007/1381893294_zps818d2c5a.jpg (http://s897.photobucket.com/user/ehansen007/media/1381893294_zps818d2c5a.jpg.html)

http://i897.photobucket.com/albums/ac177/ehansen007/1381893314_zps8a1b793a.jpg (http://s897.photobucket.com/user/ehansen007/media/1381893314_zps8a1b793a.jpg.html)

http://i897.photobucket.com/albums/ac177/ehansen007/1381893321_zps589a21c6.jpg (http://s897.photobucket.com/user/ehansen007/media/1381893321_zps589a21c6.jpg.html)

http://i897.photobucket.com/albums/ac177/ehansen007/1381893324_zps1a6530dc.jpg (http://s897.photobucket.com/user/ehansen007/media/1381893324_zps1a6530dc.jpg.html)


http://i897.photobucket.com/albums/ac177/ehansen007/1381893332_zps5871a1ec.jpg (http://s897.photobucket.com/user/ehansen007/media/1381893332_zps5871a1ec.jpg.html)

[wallace18]

Too cool! It looks like it was made to be there from the get go. Great job so far.

[Mechie3]

I got mine from protuninglab.com but I think they are the same. They were $309 including the HID conversion. Some places advertise cheaper but then charge for the HID upgrade. Make sure you have the option to select the color temp. I picked 6000K which is ICE White (slight blueish hue)

Few questions.

They show 02-04 and 05/06 camry as separate. Is there any difference except for the 05/06 lights being uglier (IMO)? The basis shape looks the same.

What is the optional warning canceler?

Can you take a pic of the beam pattern? Just hooking it up to 12V and shining it on the wall is fine. Just wondering if they used proper projectors and lenses for an HID bulb.

Thanks.

[ehansen007]

http://i897.photobucket.com/albums/ac177/ehansen007/1382067486_zps1e056deb.jpg (http://s897.photobucket.com/user/ehansen007/media/1382067486_zps1e056deb.jpg.html)
New brakes are on.

http://i897.photobucket.com/albums/ac177/ehansen007/1382067616_zpsa8aa595d.jpg (http://s897.photobucket.com/user/ehansen007/media/1382067616_zpsa8aa595d.jpg.html)
Rear end reassembled with newer hubs. Halfshafts fit too! Put in some subie 75-90S gear oil

http://i897.photobucket.com/albums/ac177/ehansen007/1382067625_zps16c34030.jpg (http://s897.photobucket.com/user/ehansen007/media/1382067625_zps16c34030.jpg.html)
Had to move the lower shock mounts due to the manual error and I wasn't happy with just redrilling so I threw a Bead on there as well. That mount takes a lot of cornering force. I hope no one else has to deal with this.

http://i897.photobucket.com/albums/ac177/ehansen007/1382067633_zps720cb572.jpg (http://s897.photobucket.com/user/ehansen007/media/1382067633_zps720cb572.jpg.html)
New front calipers under the wheels. Still haven't decided on the logo. :rolleyes:

http://i897.photobucket.com/albums/ac177/ehansen007/1382067635_zps9aff0882.jpg (http://s897.photobucket.com/user/ehansen007/media/1382067635_zps9aff0882.jpg.html)
Building to new heights. It's so great to have access to a lift.

[flynntuna]

How's this for a logo...

[ehansen007]

Another good day at EV West.

http://i897.photobucket.com/albums/ac177/ehansen007/469048B1-A6DB-4FFD-8099-1C446D241756-4846-000005AAFF880319_zpsf089b715.jpg
Put in the firewalls where we will mount the controllers

http://i897.photobucket.com/albums/ac177/ehansen007/F5801867-3A2B-4290-A0EA-9D3FEBBD1D9F-4846-000005AB0833FF30_zps05eeb4aa.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/C0C1D258-7B48-4570-84AF-5416AD038696-4846-000005AB0F1750E1_zps8f665209.jpg
Also started running all the brake lines. Ran in to trouble when I realized that I only got one 12 line two 8"" inch lines and the rest are 60". So I guess I need to buy what I need.

http://i897.photobucket.com/albums/ac177/ehansen007/9ABBC172-C806-41EC-8E6A-A2E26E1A2256-4846-000005AB160FD98D_zps6d0cca77.jpg
I look forward to the drive home even though its an hour long.

[JJ'snakepit]

WHAT A COOL THREAD!!!!! living here in SoCal I can't wait to see this in person. Great Job Eric I'll bet its really going to sound BAD ***, just the tires burning LOL...... JJ

[esff32]

That thing looks awesome Erik, can't wait to see some video. Looking forward to the rest of the build. I will catch up with you at SEMA.

[Frank818]

This build is freakin clean.

[ehansen007]

Few questions.

They show 02-04 and 05/06 camry as separate. Is there any difference except for the 05/06 lights being uglier (IMO)? The basis shape looks the same.

What is the optional warning canceler?

Can you take a pic of the beam pattern? Just hooking it up to 12V and shining it on the wall is fine. Just wondering if they used proper projectors and lenses for an HID bulb.

Thanks.

No idea on the first two questions. But this is what they look like. It's definite projectors. I looked at it and blinded myself instantly.

http://i897.photobucket.com/albums/ac177/ehansen007/5853CBAC-B193-473E-AF00-C948A9A5C8F3-1370-000001480C69B533_zpsd1abdf10.jpg (http://s897.photobucket.com/user/ehansen007/media/5853CBAC-B193-473E-AF00-C948A9A5C8F3-1370-000001480C69B533_zpsd1abdf10.jpg.html)
Projectors on

http://i897.photobucket.com/albums/ac177/ehansen007/316D9F89-9D0B-4AB7-A053-C565B6D16A31-1370-00000148046FC374_zpsd06f790e.jpg (http://s897.photobucket.com/user/ehansen007/media/316D9F89-9D0B-4AB7-A053-C565B6D16A31-1370-00000148046FC374_zpsd06f790e.jpg.html)
Nice flat beam across the top

http://i897.photobucket.com/albums/ac177/ehansen007/F9676174-5FAE-4F5C-A3AE-80610A1A453E-1370-0000014816E27EDD_zpsecdf9edb.jpg (http://s897.photobucket.com/user/ehansen007/media/F9676174-5FAE-4F5C-A3AE-80610A1A453E-1370-0000014816E27EDD_zpsecdf9edb.jpg.html)
DRL will cool with the projectors on

http://i897.photobucket.com/albums/ac177/ehansen007/9BBA324A-813B-43BC-B814-55B8DCBDD1C4-1370-000001481CFF4CF1_zpscdbea510.jpg (http://s897.photobucket.com/user/ehansen007/media/9BBA324A-813B-43BC-B814-55B8DCBDD1C4-1370-000001481CFF4CF1_zpscdbea510.jpg.html)
Halogen high beams


http://i897.photobucket.com/albums/ac177/ehansen007/B68BEAAC-7303-4D39-86D8-DFA12A40B375-1370-0000014822A8B581_zps00e6bc8d.jpg (http://s897.photobucket.com/user/ehansen007/media/B68BEAAC-7303-4D39-86D8-DFA12A40B375-1370-0000014822A8B581_zps00e6bc8d.jpg.html)
This is how you know you got the real deal and why it's ~$100 upgrade. Unfortunately the Changlish gives away it's origin. :)

[Mechie3]

Have the high voltage inside!??! Hahaha!

Thanks for the pics.

I think they might be using rebased HID bulbs in a halogen housing. The cutoff is clean, but the fill under the cutoff looks focused. I might go without the HID and then do a TSX projector retrofit. I did that on my 06 WRX and it was incredible. I do prefer the look of those lights though. They look more modern and upscale.

Not my car, but how it looked (same car/retrofit)
http://www.msprotege.com/members/joefufu/CIMG0859.jpg

[ehansen007]

New gauges from speedhut

http://i897.photobucket.com/albums/ac177/ehansen007/E3DF9E81-BADA-4746-8181-F691C63BE1A7-3214-0000035F3FC95356_zpsebe294a6.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/84D0A71C-2EFC-42A9-8B92-35D52C2AFEBF-3214-0000035F465C6AE8_zps638ec81a.jpg

[mikey likes it!]

New gauges from speedhut

http://i897.photobucket.com/albums/ac177/ehansen007/E3DF9E81-BADA-4746-8181-F691C63BE1A7-3214-0000035F3FC95356_zpsebe294a6.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/84D0A71C-2EFC-42A9-8B92-35D52C2AFEBF-3214-0000035F465C6AE8_zps638ec81a.jpg

Your neighbors will love you even more on those early morning Cars n Coffee runs ......

[ehansen007]

LOL. I didn't even think about that!! Good point.

[ehansen007]

Finished the front brake lines today. Only had to flare one line. I wanted to make it as clean as possible.

http://i897.photobucket.com/albums/ac177/ehansen007/90B037E6-4C4C-4C62-AEE5-66A929E260E0-3782-00000459FC5E076E_zpse1c5f71f.jpg
This short run was a little challenging and finally gave in and did it by hand.

http://i897.photobucket.com/albums/ac177/ehansen007/DD39BC10-FA0C-4254-A8EC-12BF0EB3E517-3782-0000045A32BFAC2D_zpsad794f20.jpg

http://i897.photobucket.com/albums/ac177/ehansen007/BCA1C39E-A78E-45FA-B46E-7D771B3A8E22-3782-0000045A2BED59BA_zps3c59caf4.jpg
The mounting collars that came with the braided lines worked great with the larger clips when mounting to the uprights. As with the rear I was able to put the extra hardware to good use.

http://i897.photobucket.com/albums/ac177/ehansen007/07434FB9-4212-43D3-97E3-F1705F480EE5-3782-0000045A23D990DE_zps8da1cfb0.jpg

[RM1SepEx]

Your rear LCA bushing is upside down in the photo above, it is supposed to have the "wiggle" side down.

[ehansen007]

Yup! But this was the way it went in without binding up the suspension. I figured the less binding the better. It didn't change the geometry any I didn't see any reason why this would be any more stress in the bushing. Actually I think it's now has less.

[Erik W. Treves]

looking good

[Xusia]

Yup! But this was the way it went in without binding up the suspension. I figured the less binding the better. It didn't change the geometry any I didn't see any reason why this would be any more stress in the bushing. Actually I think it's now has less.

Yeah, I've wondered about that too. I think I heard they were not symetrical? Anyone??

[RM1SepEx]

they are not symetrical

[Bob_n_Cincy]

Yup! But this was the way it went in without binding up the suspension. I figured the less binding the better. It didn't change the geometry any I didn't see any reason why this would be any more stress in the bushing. Actually I think it's now has less.

I believe the legs of the bushing are different length from the centerline of the hole. Flipping them over will move the back of the LCA out. That in turn moves the ball joint forward. That in turn give you more tire clearance between the back of the tire and the frame.
Bob

[Mechie3]

The mounting collars that came with the braided lines worked great with the larger clips when mounting to the uprights.

The collars are the pieces you rivet to the frame? I have braided lines not from FFR and mine sit too loose on those pieces with the supplied clips.

[RM1SepEx]

mine are non F5 braided line and my clips are too tight!

[Kalstar]

The collars are the pieces you rivet to the frame? I have braided lines not from FFR and mine sit too loose on those pieces with the supplied clips.

I do not know how I missed this entire thread. Man, I am in love!

[freds]

Yup! But this was the way it went in without binding up the suspension. I figured the less binding the better. It didn't change the geometry any I didn't see any reason why this would be any more stress in the bushing. Actually I think it's now has less.

That is exactly what I did too.
The legs do have a max 1/4" difference center of bolt hole-- to center of bushing. The vertical position of the center of the bushing is symmetrical (best I could measure)
I chose to use the front bushing mounting holes as my reference (didn't want to elongate any of those mounting holes in the Chassis)....then checked for the freest pivot action and found "wiggle side" up was best...it was also coincidentally the way that also put the rear mounting holes closer to alignment with the as supplied chassis holes.

Also seeing how some of the builds have adjusted things to get the LCA's installed. I figured this choice was comparatively very low risk at worst.

fred

[ehansen007]

The collars are the pieces you rivet to the frame? I have braided lines not from FFR and mine sit too loose on those pieces with the supplied clips.

Yes, I'm referring to the tabs that came on the rear braided lines and the bolt like collars that came on the front ones. If you look closely at these two photos, you'll see that I'm referring to. The rear came with these.

http://i897.photobucket.com/albums/ac177/ehansen007/C0C1D258-7B48-4570-84AF-5416AD038696-4846-000005AB0F1750E1_zps8f665209.jpg

The front came with these and the rubberized frame clips were the perfect size to hold them to the upright. Clean!

http://i897.photobucket.com/albums/ac177/ehansen007/BCA1C39E-A78E-45FA-B46E-7D771B3A8E22-3782-0000045A2BED59BA_zps3c59caf4.jpg

[ehansen007]

That is exactly what I did too.
The legs do have a max 1/4" difference center of bolt hole-- to center of bushing. The vertical position of the center of the bushing is symmetrical (best I could measure)
I chose to use the front bushing mounting holes as my reference (didn't want to elongate any of those mounting holes in the Chassis)....then checked for the freest pivot action and found "wiggle side" up was best...it was also coincidentally the way that also put the rear mounting holes closer to alignment with the as supplied chassis holes.

Also seeing how some of the builds have adjusted things to get the LCA's installed. I figured this choice was comparatively very low risk at worst.

fred

When you compare it to the amount of binding at the rear it's moot! While I understand you want huge rear toe in at the rear on AWD, I can figure out why there is so much implied toe at the rear with the control arms. I haven't done any final adjustments but getting the rear contol arms lined up with the hub was a challenge. If the bushings weren't rubber I would have never gotten them on. Anyone else notice this?

[wallace18]

When you compare it to the amount of binding at the rear it's moot! While I understand you want huge rear toe in at the rear on AWD, I can figure out why there is so much implied toe at the rear with the control arms. I haven't done any final adjustments but getting the rear contol arms lined up with the hub was a challenge. If the bushings weren't rubber I would have never gotten them on. Anyone else notice this?
They sure made me work for it. Seems Ok when everything is all together though IMO.

[Frank818]

33, how high RPM does this electric engine go? I see your 8k RPM gauge, but wonder if it actually stops below.

[ehansen007]

The "knee" of the torque band drops off steeply at 5k RPM. While I can continue to spin it well beyond, it's better to upshift and re-engage that sweet, bottom end power. There is no fear of blowing an electric motor like an ICE motor. The only moving parts in this case are the shaft, and the bearings. No brushes to replace either at it's an AC motor and not DC.

[Frank818]

Can't wait to see that on the streets. :)

[ehansen007]

http://i897.photobucket.com/albums/ac177/ehansen007/1F046228-3217-4280-840B-C93205350726-1292-000001921EAB50DD_zpsda87f890.jpg

Got the brake lines bled and started mounting the controllers today. As soon as I got one I noticed I couldn't get the battery box in! My first run in with tight quarters. So I'm going to finalize the boxes and get them in so we can remount the controllers.

http://i897.photobucket.com/albums/ac177/ehansen007/C5BCA8FD-9625-46CE-A55F-6185E04640EE-1292-00000191EAEEC7F8_zps69fe4602.jpg
Also started working on my gauge cluster. Since I'm not using the stock one I need to fab my own.

http://i897.photobucket.com/albums/ac177/ehansen007/90F9F338-5C57-4BB6-820E-F098AC2DA905-1292-000001932B4AD6D6_zpsde2cbedc.jpg
Because the cutout is curved, it bows the panel and makes the gauges look like gecko eyes. So I made these offset bezel shims to even it out.

http://i897.photobucket.com/albums/ac177/ehansen007/F0A70A1B-CBDB-4550-A0DB-3C92EF3AFCF5-1292-000001933A13CD58_zpse312c788.jpg
Finalized panel.

http://i897.photobucket.com/albums/ac177/ehansen007/F38F5E06-783B-4728-9A12-C684EFC45E40-1292-0000027EE584D120_zpsa36903b9.jpg
How about a little CF? :)

http://i897.photobucket.com/albums/ac177/ehansen007/476EF6AC-99BB-4012-B15D-5550602882FB-1292-0000027F0696A8A5_zps1a37231d.jpg
Mockup.

[Bob_n_Cincy]

Great job Erik
I'm still on the fence about using the stock unit,
Bob

[longislandwrx]

Where's the flux capacitor mounted?

[Mechie3]

Nice CF! What did you cut it with?

[Canadian818]

Real CF? Can you buy it in panels like that?

[Wayne Presley]

meh, looks ok but you forgot the coolant temp and oil pressure gauges

http://i897.photobucket.com/albums/ac177/ehansen007/F38F5E06-783B-4728-9A12-C684EFC45E40-1292-0000027EE584D120_zpsa36903b9.jpg

[David Hodgkins]

meh, looks ok but you forgot the coolant temp and oil pressure gauges

http://i897.photobucket.com/albums/ac177/ehansen007/F38F5E06-783B-4728-9A12-C684EFC45E40-1292-0000027EE584D120_zpsa36903b9.jpg

Everybody's a critic...

;)

[Silvertop]

meh, looks ok but you forgot the coolant temp and oil pressure gauges

http://i897.photobucket.com/albums/ac177/ehansen007/F38F5E06-783B-4728-9A12-C684EFC45E40-1292-0000027EE584D120_zpsa36903b9.jpg

More importantly, the Flux Capacitor Transpixilator Gauge is missing! :)

[Frank818]

Real CF? Can you buy it in panels like that?

I am asking the same question.

[longislandwrx]

My question is..

How difficult would it be to install the charging equipment needed to utilize the Tesla supercharging stations that are popping up all over?

http://green.autoblog.com/2013/05/30/tesla-supercharger-network-goes-nationwide-gets-faster-w-video/



Frank/Canadian, In the past I've purchased my carbon from
http://www.protechcomposites.com/

one of the best thing they have is scraps! For $35 you get a pound which is a lot of pieces. good for spacers trim bezels veneers etc

[ehansen007]

Haha. Yes that is the Xantrex Pro and it does the following

Read your battery bank like a fuel gauge
Provides critical information about the status of your battery bank
Displays voltage, current, consumed amphours and remaining battery capacity
Secondary battery bank voltage monitoring
Auto sensing battery voltage inputs
And yes, it can monitor engine/controller temp.

As for the CF, the company I'm working with (EV West) also owns gravity skateboards so they have a lot of different materials which they surface their boards with. This stuff is really thin and flexible. I cut it on the bandsaw and used a rotary tool to cut the larger holes.

[Wayne Presley]

When ever you cut CF, have the shop vac running as the dust is really bad for you.

[ehansen007]

Agreed And definitely wear a mask. The problem with carbon is that the body won't reject it so whatever you inhale, you keep forever.

[Mechie3]

It's conductive too. Good way to kill a CNC machine by filling it full of conductive fine powder.

[Xusia]

Eric, I didn't get a clear sense. Is it a vinyl wrap? I'm interested in a good looking 3D CF vinyl wrap. I plan to use it on some body panels like the hood, on some interior parts like the dash, and some other small bits.

[Wayne Presley]

Not a wrap, that is sheets of CF.

[VD2021]

When ever you cut CF, have the shop vac running as the dust is really bad for you.


Agreed And definitely wear a mask. The problem with carbon is that the body won't reject it so whatever you inhale, you keep forever.

This should be applied to epoxy or poly resin and fg also.

[ehansen007]

That's correct. They are sheets and can't really fold or be used as a wrap.

[wleehendrick]

Hi Eric,

I got over to EV West to check it out today... looks great, when you going to put the tranny in and take it for a spin? The NRG seats are nice; I'll get in touch with you about ordering a pair.

[Canadian818]

Hi Eric,

I got over to EV West to check it out today... looks great, when you going to put the tranny in and take it for a spin? The NRG seats are nice; I'll get in touch with you about ordering a pair.

Which NRG seats? Any pics?

[BrandonDrums]

How's this for a logo...

http://thefactoryfiveforum.com/attachment.php?attachmentid=22636&d=1382120205

This is an awesome logo. It's like if Yosemite Sam had an electric mustache. Will you be putting mudflaps on this time machine?

[Oppenheimer]

http://thefactoryfiveforum.com/attachment.php?attachmentid=22636&d=1382120205

Plus if you live in San Diego, everyone will think you are a pro football player.

[ehansen007]

Hey Guys, time for an update. Yesterday was a day where we took all our steps forward and not one step back! So I was very happy. Swaps: Had to swap out the rear rotors as I found out that a 98 GC8 takes vented rears! You can't get GC8 Parts locally so thank god they are simply 98 Legacy AWD Turbo rotors and are semi affordable at $60 each!

http://www.partsgeek.com/assets/dimage/thumb/1095327.jpg

Also, we swapped out the 2pc Pressure plate spring wedge collar after turning it into 3 pieces. After hearing of a horror story from Big E (Treves) at SEMA I decided to upgrade to this bad boy so I'd never have to replace it again (hopefully)

http://www.streettunedmotorsports.com/parts/b/act_monoloc_pull_type_clutch_evo_wrx_sti_884006p.j pg

[ehansen007]

So moving more forward-er, we focused mostly on battery installation yesterday. I'm honestly amazed at the amount of detail and thoroughness the EV West team (Matt and Michael) pour into their designs. While I'm doing most of the hard labor they have given me guidance to provide the safest and most structurally sound set up imaginable. In fact, impact and rollover has been discussed several times when talking about battery security so you can tell they actually race EVs and intend to race this one with me!

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_20131118_101035_zpsc0757faa.jpg (http://s897.photobucket.com/user/ehansen007/media/IMG_20131118_101035_zpsc0757faa.jpg.html)
These boxes are 3/16 aluminum and have become and integral part of the chassis as we have countersunk black hardened M10 allens in the bottom and used aluminum bars tapped for M8 Stainless button head allens to secure the batteries in the boxes. Couple that with routing for the glan nuts and copper coupling straps for the rear and we're talking about an incredible amount of work to secure batteries!

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_20131118_124759_zps34349db5.jpg (http://s897.photobucket.com/user/ehansen007/media/IMG_20131118_124759_zps34349db5.jpg.html)
Pre-final tranny install

http://i897.photobucket.com/albums/ac177/ehansen007/44875A91-AD39-43F5-8DF6-381AC2543543-2145-000003BE072CF79B_zps2fd1e4f1.jpg (http://s897.photobucket.com/user/ehansen007/media/44875A91-AD39-43F5-8DF6-381AC2543543-2145-000003BE072CF79B_zps2fd1e4f1.jpg.html)
Matt also fabbed these great copper tie straps to connect the two boxes together and then shrink wrapped them to avoid any issues. You can see it in the right box

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_20131118_174230_zpsa0828c00.jpg (http://s897.photobucket.com/user/ehansen007/media/IMG_20131118_174230_zpsa0828c00.jpg.html)
Top view

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_20131118_174414_zps91b805f6.jpg (http://s897.photobucket.com/user/ehansen007/media/IMG_20131118_174414_zps91b805f6.jpg.html)
Battery bars connecting each cell. Funny thing here is that you need to be very careful not to touch the straps to each other! They showed me the various ways this can happen and I did my best to avoid arcing them however they failed to tell me that sometimes when threading the bolt in, the strap can sometimes grab the bolt and it will swing over. I proved this theory unfortunately but it just produced a small spark (Thank god). I blame them entirely as I am an idiot and have put my life in their hands and will kill myself if they do not intervene! LOL :)

[stack]

Great work Erik. Need to get back out there to check it out.

stack

[wleehendrick]

Which NRG seats? Any pics?

https://www.getnrg.com/products/interior-products/seats/carbon-fiber-bucket-seats/frp-300

(although the link says carbon fiber, that model is fiberglass) Erik posted pictures of the seats earlier in this thread.

[Bob_n_Cincy]

Funny thing here is that you need to be very careful not to touch the straps to each other! They showed me the various ways this can happen and I did my best to avoid arcing them however they failed to tell me that sometimes when threading the bolt in, the strap can sometimes grab the bolt and it will swing over. I proved this theory unfortunately but it just produced a small spark (Thank god). I blame them entirely as I am an idiot and have put my life in their hands and will kill myself if they do not intervene! LOL :)

Looking Great Eric.
I have a set of insulated wrenches just for assembling batteries.
Pay particular attention to wire chaffing possibilities. On rough roads every wire bounces.
I have even seen 2 wires tied together with tie wrap wear the insulation off.
Bob.

[ehansen007]

https://www.getnrg.com/products/interior-products/seats/carbon-fiber-bucket-seats/frp-300

(although the link says carbon fiber, that model is fiberglass) Erik posted pictures of the seats earlier in this thread.

https://www.getnrg.com/files/node_images/RSC-300%20Back.jpg

https://www.getnrg.com/files/node_images/RSC-300%20Front.jpg

https://www.getnrg.com/files/node_images/RSC-300%20Side.jpg

[metalmaker12]

So moving more forward-er, we focused mostly on battery installation yesterday. I'm honestly amazed at the amount of detail and thoroughness the EV West team (Matt and Michael) pour into their designs. While I'm doing most of the hard labor they have given me guidance to provide the safest and most structurally sound set up imaginable. In fact, impact and rollover has been discussed several times when talking about battery security so you can tell they actually race EVs and intend to race this one

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_20131118_101035_zpsc0757faa.jpg (http://s897.photobucket.com/user/ehansen007/media/IMG_20131118_101035_zpsc0757faa.jpg.html)
These boxes are 3/16 aluminum and have become and integral part of the chassis as we have countersunk black hardened M10 allens in the bottom and used aluminum bars tapped for M8 Stainless button head allens to secure the batteries in the boxes. Couple that with routing for the glan nuts and copper coupling straps for the rear and we're talking about an incredible amount of work to secure batteries!

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_20131118_124759_zps34349db5.jpg (http://s897.photobucket.com/user/ehansen007/media/IMG_20131118_124759_zps34349db5.jpg.html)
Pre-final tranny install

http://i897.photobucket.com/albums/ac177/ehansen007/44875A91-AD39-43F5-8DF6-381AC2543543-2145-000003BE072CF79B_zps2fd1e4f1.jpg (http://s897.photobucket.com/user/ehansen007/media/44875A91-AD39-43F5-8DF6-381AC2543543-2145-000003BE072CF79B_zps2fd1e4f1.jpg.html)
Matt also fabbed these great copper tie straps to connect the two boxes together and then shrink wrapped them to avoid any issues. You can see it in the right box

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_20131118_174230_zpsa0828c00.jpg (http://s897.photobucket.com/user/ehansen007/media/IMG_20131118_174230_zpsa0828c00.jpg.html)
Top view

http://i897.photobucket.com/albums/ac177/ehansen007/IMG_20131118_174414_zps91b805f6.jpg (http://s897.photobucket.com/user/ehansen007/media/IMG_20131118_174414_zps91b805f6.jpg.html)
Battery bars connecting each cell. Funny thing here is that you need to be very careful not to touch the straps to each other! They showed me the various ways this can happen and I did my best to avoid arcing them however they failed to tell me that sometimes when threading the bolt in, the strap can sometimes grab the bolt and it will swing over. I proved this theory unfortunately but it just produced a small spark (Thank god). I blame them entirely as I am an idiot and have put my life in their hands and will kill myself if they do not intervene! LOL :)


This is soooo
Cool

[flynntuna]

I'm really liking this build. The level of quality and finish is outstanding

[Cees]

I love your workstyle, build and result. Excellent.

Any plans for adding a getto blaster with V8 and V12 sounds?

[ehansen007]

That's the plan if I can only find a high quality source. I've tried everywhere too. Most guys that have started a business have had a hard time sustaining it because full EVs still aren't mainstream.

[rtz]

What's next? How soon till your driving?

[Rasmus]

Eric, I'm having a hard time understanding why you'd install a transmission when running an electric motor. Seems you get consistent torque from 1 rpm to about 5000 rpm. Why not install just a rear differential with a 2.4 or so final drive. On your 24.8" tall tires you've have a speed range of 0-154mph and no transmission at all. Plus the rear diff's final drive acts as a torque multiplier so you'd be putting a crazy (~175ftlb * 2.4) 420 ftlb to those skinny tires at every RPM.

No flywheel, no clutch, no trans, no shifting. Just tire smoke and the smell of ozone.

[Bob_n_Cincy]

Eric, I'm having a hard time understanding why you'd install a transmission when running an electric motor. Seems you get consistent torque from 1 rpm to about 5000 rpm. Why not install just a rear differential with a 2.4 or so final drive. On your 24.8" tall tires you've have a speed range of 0-154mph and no transmission at all. Plus the rear diff's final drive acts as a torque multiplier so you'd be putting a crazy (~175ftlb * 2.4) 420 ftlb to those skinny tires at every RPM.

No flywheel, no clutch, no trans, no shifting. Just tire smoke and the smell of ozone.

You want tire smoke:
175 ft-lbs motor x 3.454 (first gear) x 3.9 (diff) = 2357 ft-lbs to rear axle. That's over 1.2 G acceleration from 0 to 27 mph @5000RPM.
175 ft-lbs motor x 2.062 (second gear) x 3.9 (diff) = 1707 ft-lbs to rear axle. That's over 0.8 G acceleration from 0 to 44 mph @5000 RPM.
Bob

[ehansen007]

Haha. Good point bob. Put simply, I like to shift and with each gear I get the sweet spot for power to the wheels. From my understanding, for single gear applications you want a motor/controller combo that can spin up to around 10K. Also, the subaru tranny is cheap and it fits right into the car! :) The idea for this was to build something that could drop right in and be somewhat affordable. That plan flew out the window the minute I saw two motors stuffed into the same can. :) Now that the EV West guys are familiar with the kit, they'll put something together for those interested.

e

[ehansen007]

Things are moving along although with the commute and busy life schedule it's hard to get down there more than two days a week.


http://i897.photobucket.com/albums/ac177/ehansen007/0DA6BE32-8D75-4501-8BC9-9678B5EF0220-2987-0000042C5E0DA3BB_zps18ffeb4a.jpg (http://s897.photobucket.com/user/ehansen007/media/0DA6BE32-8D75-4501-8BC9-9678B5EF0220-2987-0000042C5E0DA3BB_zps18ffeb4a.jpg.html)
http://i897.photobucket.com/albums/ac177/ehansen007/6CFA3C20-8CA1-4DB7-B7B7-6BD69D9A409B-2987-0000042C65707966_zps19044240.jpg (http://s897.photobucket.com/user/ehansen007/media/6CFA3C20-8CA1-4DB7-B7B7-6BD69D9A409B-2987-0000042C65707966_zps19044240.jpg.html)
Got the clutch line run and bled and it seems to be working well. What a PIA to bleed that was! Not sure I'm happy with the tension on this line though.

http://i897.photobucket.com/albums/ac177/ehansen007/45071D4B-E77B-47B9-9599-818B70B78A76-2987-0000042C9F08E6D5_zpsb25b053f.jpg (http://s897.photobucket.com/user/ehansen007/media/45071D4B-E77B-47B9-9599-818B70B78A76-2987-0000042C9F08E6D5_zpsb25b053f.jpg.html)
I also got the shifter and in and cables routed and I noticed I had the cables swapped earlier which was why one was short. So it all went in fine and I also bent the brackets so that everything was pretty straight on so there was no binding.

http://i897.photobucket.com/albums/ac177/ehansen007/3E2E0BB9-6951-4844-B6A1-EC22E0DCCCE7-2987-0000042C7A201D99_zps1533f94a.jpg (http://s897.photobucket.com/user/ehansen007/media/3E2E0BB9-6951-4844-B6A1-EC22E0DCCCE7-2987-0000042C7A201D99_zps1533f94a.jpg.html)

http://i897.photobucket.com/albums/ac177/ehansen007/7C7CB962-1A54-4205-8B9F-9D80C4505E32-2987-0000042C365A6DD5_zps2c2251f3.jpg (http://s897.photobucket.com/user/ehansen007/media/7C7CB962-1A54-4205-8B9F-9D80C4505E32-2987-0000042C365A6DD5_zps2c2251f3.jpg.html)
http://i897.photobucket.com/albums/ac177/ehansen007/2AF85820-5180-475D-A4D0-1A5CE680D465-2987-0000042C4B1E904A_zpse72f6194.jpg (http://s897.photobucket.com/user/ehansen007/media/2AF85820-5180-475D-A4D0-1A5CE680D465-2987-0000042C4B1E904A_zpse72f6194.jpg.html)
Last we got the charger in there which is the top of the line ElCon. Matt was a huge help in fabbing up some simple brackets so it was functional and looked good.

So now, I've the entire drivetrain working and just need to focus on wiring. I picked up a simple hot rod harness off ebay and what I need now is the plugs and schematic for the wires coming off the steering column. I'll start looking around.

[charkilah]

239752397223973

I absolutely love this build. I have dreamed of this ever since the 818 was announced, and now that HPEVS came out with the 35X2, its a perfect combination. A while ago I made a couple of charts that calculate the torque to the wheels and the acceleration. Obviously some approximations and assumptions were made, but they are generally correct. I hope you find them interesting.

The max tire traction is calculated for a rear wheel drive vehicle with a locked differential. The weight distribution and leverage from a raised center of gravity are in the formula.

[Frank818]

Nice calcs!

Do you think these formulas could apply for gas engines as well?
If yes I'd like to understand what you are using and how to calculate all this. In another thread would be great to present all this.

[ehansen007]

Decided to bring the 818 home for the holidays. The guys at EVW weren't ready to wire it and I can get so much more done at home it's great.

Before I left we set it up on the scales to see what we had. I guessed 1700.

http://i897.photobucket.com/albums/ac177/ehansen007/E6ACA745-4279-45CB-80E2-4A496F926535-10425-00001097A46F48A7_zpsc276b136.jpg (http://s897.photobucket.com/user/ehansen007/media/E6ACA745-4279-45CB-80E2-4A496F926535-10425-00001097A46F48A7_zpsc276b136.jpg.html)

http://i897.photobucket.com/albums/ac177/ehansen007/45EC48A6-7833-4021-8424-B11113F92823-10425-000010979CBE7474_zps623abfa5.jpg (http://s897.photobucket.com/user/ehansen007/media/45EC48A6-7833-4021-8424-B11113F92823-10425-000010979CBE7474_zps623abfa5.jpg.html)

http://i897.photobucket.com/albums/ac177/ehansen007/DC884D2E-12F3-4E48-A8A3-2CA8D27A7256-10425-00001098130AE55B_zps2010002c.jpg (http://s897.photobucket.com/user/ehansen007/media/DC884D2E-12F3-4E48-A8A3-2CA8D27A7256-10425-00001098130AE55B_zps2010002c.jpg.html)

[ehansen007]

Once I got it home I went right to work making the battery box covers.

http://i897.photobucket.com/albums/ac177/ehansen007/675B096F-9A8F-435C-AD88-D5BC97C9A333-13099-000013CBC8ACC701_zpsbe16928c.jpg (http://s897.photobucket.com/user/ehansen007/media/675B096F-9A8F-435C-AD88-D5BC97C9A333-13099-000013CBC8ACC701_zpsbe16928c.jpg.html)I used Starboard with carbon Fiber for lightweight. First I built the frames.

http://i897.photobucket.com/albums/ac177/ehansen007/B318D18B-46F1-4ED0-9E3B-C060C773B2A3-13099-000013CF369210F1_zpsd7f797e8.jpg (http://s897.photobucket.com/user/ehansen007/media/B318D18B-46F1-4ED0-9E3B-C060C773B2A3-13099-000013CF369210F1_zpsd7f797e8.jpg.html)
Then I routered the edge to counter sink the lid into the box. This was a challenge. The first time using a router was a learning experience. I bought a nice Bosch router only to be thwarted by the $2 adjustment guide it came with. No matter what I did that thing would slide on me and screw up my routing on the lid. I managed to get through it though. You can see the offramp I took here on the way to cuss-ville.

http://i897.photobucket.com/albums/ac177/ehansen007/1AECE74C-6332-457D-83AB-7C9197785295-13099-000013CF3C9B51C7_zpseefd824c.jpg (http://s897.photobucket.com/user/ehansen007/media/1AECE74C-6332-457D-83AB-7C9197785295-13099-000013CF3C9B51C7_zpseefd824c.jpg.html)
Then I traced the carbon and bonded it to the frame.

http://i897.photobucket.com/albums/ac177/ehansen007/1D61A606-3A68-479F-ADF1-0734E11A1C55-13099-000013CF423DEB02_zps5d8a5610.jpg (http://s897.photobucket.com/user/ehansen007/media/1D61A606-3A68-479F-ADF1-0734E11A1C55-13099-000013CF423DEB02_zps5d8a5610.jpg.html)
All done! Need to secure them now.

[ehansen007]

Next I went to work building brackets to secure the radiator for the water cooling system.

http://i897.photobucket.com/albums/ac177/ehansen007/A7CE6874-792F-4FC7-90DA-F6F120D14161-13099-000013CBD47222FC_zps3222d901.jpg (http://s897.photobucket.com/user/ehansen007/media/A7CE6874-792F-4FC7-90DA-F6F120D14161-13099-000013CBD47222FC_zps3222d901.jpg.html)

http://i897.photobucket.com/albums/ac177/ehansen007/861F8A90-4B78-4E40-87CF-44D15126C67C-13099-000013CC1190EE72_zpse540e0c6.jpg (http://s897.photobucket.com/user/ehansen007/media/861F8A90-4B78-4E40-87CF-44D15126C67C-13099-000013CC1190EE72_zpse540e0c6.jpg.html)
Who needs a water jet? Me probably.

http://i897.photobucket.com/albums/ac177/ehansen007/3805870D-AC44-4A83-A016-A4D591ABC86A-13099-000013CC1C0D4B9C_zps4f98388b.jpg (http://s897.photobucket.com/user/ehansen007/media/3805870D-AC44-4A83-A016-A4D591ABC86A-13099-000013CC1C0D4B9C_zps4f98388b.jpg.html)

[ehansen007]

Last I said to myself "there has to be a better way to mount this shifter." With the magic of the forums I set off on task.

I started by disassembling the shifter and taking the shaft out. I heated up the shaft (after removing it from the housing) and bent it straight.

http://i897.photobucket.com/albums/ac177/ehansen007/4D9EDF55-E8FF-4CD2-B19D-1A55D207B893-13099-000013CC35F58D81_zps8cb8f8af.jpg (http://s897.photobucket.com/user/ehansen007/media/4D9EDF55-E8FF-4CD2-B19D-1A55D207B893-13099-000013CC35F58D81_zps8cb8f8af.jpg.html)
Then I built a platform and bolted it to the subframe using Rivnuts.

http://i897.photobucket.com/albums/ac177/ehansen007/7096B2D9-CC64-4079-AC5C-951E3944E661-13099-000013CC3D3AFA22_zps2f0557a1.jpg (http://s897.photobucket.com/user/ehansen007/media/7096B2D9-CC64-4079-AC5C-951E3944E661-13099-000013CC3D3AFA22_zps2f0557a1.jpg.html)

http://i897.photobucket.com/albums/ac177/ehansen007/FF9D5E0C-AF55-407F-8D1C-8308780A2FE9-13099-000013CC450C9DBE_zpsb7df46d8.jpg (http://s897.photobucket.com/user/ehansen007/media/FF9D5E0C-AF55-407F-8D1C-8308780A2FE9-13099-000013CC450C9DBE_zpsb7df46d8.jpg.html)
You can see the spacers I used. I actually got them from Ace hardware and doubled them with spacers inside for strength.

http://i897.photobucket.com/albums/ac177/ehansen007/C31E3016-6648-4959-A047-8DCCCBA33B8B-13099-000013CC55028ACD_zps115642e1.jpg (http://s897.photobucket.com/user/ehansen007/media/C31E3016-6648-4959-A047-8DCCCBA33B8B-13099-000013CC55028ACD_zps115642e1.jpg.html)

http://i897.photobucket.com/albums/ac177/ehansen007/74210262-2CF0-4A85-8292-DDE24E5A6D1D-13099-000013CC4CDA1047_zpse520d9f2.jpg (http://s897.photobucket.com/user/ehansen007/media/74210262-2CF0-4A85-8292-DDE24E5A6D1D-13099-000013CC4CDA1047_zpse520d9f2.jpg.html)

Look how much happier he is!
From my perspective, this is an easy thing to do and should be way better than mounting it to the top. It doesn't interfere with the seats and should make building a custom center console much easier.

[freds]

That's a great solution, i am definitely going to copy that...very elegant, thanks.

fred

[Frank818]

This is the lightest 818 so far. lolll I know, it won't stay like that. :)

How are you expecting the airflow to go through your small triple rads on top of the tranny?

[Junty]

Great job on customizing the stock shifter - thanks for sharing this. I really like the VCP shifter kit - however with so many extra bits we can keep adding, I need to draw the line somewhere on what the budget will end up becoming... I love this modification and sorry Wayne - but I can now use the VCP shifter budget on something more beneficial, like turbo, intercooler or ECU...

[Canadian818]

Great job on customizing the stock shifter - thanks for sharing this. I really like the VCP shifter kit - however with so many extra bits we can keep adding, I need to draw the line somewhere on what the budget will end up becoming... I love this modification and sorry Wayne - but I can now use the VCP shifter budget on something more beneficial, like turbo, intercooler or ECU...

My thoughts exactly!

[Xusia]

This is basically the same idea I got after seeing the other shifter mod that was mounted under the rails (but from underneath). Thanks for pioneering this mod! :)

[longislandwrx]

Very nice. What are the frames of those lids made of is it just black plywood?


This is basically the same idea I got after seeing the other shifter mod that was mounted under the rails (but from underneath). Thanks for pioneering this mod! :)

Alhough, he has the luxury of not needing room for 400 wires going underneath. If you are doing a traditional build using an aluminum bracket that mounts underneath like I designed might be a better fit.

[508wrx]

I'm a massive fan of this build. Keep up the sick work!

[David Hodgkins]

Hey Mr. Hansen,

Give me a call. I wanna see the build!

Mr. Hodgkins :)

[ehansen007]

Got a few things done during the holidays although not at much as I hoped!

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/621B86FB-77C6-459B-9473-9F2F5F3DD928_zps0mkukeqb.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/621B86FB-77C6-459B-9473-9F2F5F3DD928_zps0mkukeqb.jpg.html)
Needed to make a battery holder for my small motorcycle battery. Wanted to put it on this side of the chassis to offset the drive. I would have liked to put it lower but it would have been a pain.

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/3BA7CF53-88C0-4AA5-8725-0D31D505DCD2_zpstlsedqge.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/3BA7CF53-88C0-4AA5-8725-0D31D505DCD2_zpstlsedqge.jpg.html)
First I welded up a small frame out of angled steel.

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/98151E79-9200-4D62-BF56-8C985B924679_zpsvlc62idr.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/98151E79-9200-4D62-BF56-8C985B924679_zpsvlc62idr.jpg.html)
Then I added a leg for support.

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/A34BD565-D5BE-4A86-9863-C571525145F1_zpsnqfhjmga.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/A34BD565-D5BE-4A86-9863-C571525145F1_zpsnqfhjmga.jpg.html)
Voila! Love making stuff like this.

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/2BFDD910-9139-43C0-8F0A-0C985C04CD5B_zpsnnylxfgu.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/2BFDD910-9139-43C0-8F0A-0C985C04CD5B_zpsnnylxfgu.jpg.html)

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/A8621318-D7DC-4A4E-BC71-5BB8B552F046_zpsjrcp7ygb.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/A8621318-D7DC-4A4E-BC71-5BB8B552F046_zpsjrcp7ygb.jpg.html)
Finally I made a brace to hold it in. I plan on dipping this with Plasti-dip to make it non conductive.

[ehansen007]

Next I welded in some tabs for my NRG seat brackets to mount to. Next I need to make seat harness mounts too.

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/7F1576BC-D4B8-4841-9964-1662A00E29DF_zpsn55inzky.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/7F1576BC-D4B8-4841-9964-1662A00E29DF_zpsn55inzky.jpg.html)

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/29176571-52B6-4A90-A476-4650587DD566_zpskqq3smqs.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/29176571-52B6-4A90-A476-4650587DD566_zpskqq3smqs.jpg.html) Love these seats. They fit right in the spot provided.

[AZPete]

Why do you need a motorcycle battery with all the other battery power you have? For the microwave?

[Canadian818]

Are you going to mount the harness to the square bar like we talked about?

[ehansen007]

I will be using a motorcycle battery because I will have a 150V system running the motor but will still need to convert to 12V for all other functions and must have a source of power to start up the car and open the contactors.

On the harness, I'm not sure where I"m going to mount those. It will be harder for me to use the square bar since I have a controller on the back of the firewall.

[Frank818]

Does this mean a car like Tesla has a 12v battery too?

[Bob_n_Cincy]

Does this mean a car like Tesla has a 12v battery too?

All road worthy EV cars have a 12v system. Some of my electric class 8 trucks have 24v systems. Required for hazard lights and such in case of a propulsion battery fault.
36 & 48 volt golf carts do not have a 12v system.
Bob

[clintavo]

Majorly impressive!

For a track day, would a portable generator (in the pax seat area?) add sufficient range for a 60 to 90 mile one-way drive?

Could you do 20 minutes on track, with an hour to charge in between?

[ehansen007]

I will tow for track days. My goal this year is to do the EV track day at Laguna Seca in June along with EV West and see how we do.

[David Hodgkins]

Erik,

The guy I've been shuttling to and from work got his car back so I'm finally free to check out the build! When are you free?

:)

[ehansen007]

Picked up a pedal from a Prius to install. Using the starboard I created some spacing to get the proper distances which seems to be 2.75" to the right of the brake and 2" under (closer to the firewall). The firewall flexes a bit however it's not noticeable at the pedal. Still I may make a brace for it.

URL=http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/9225A3EE-29E3-4483-A0C2-BD69D47C3635_zpsiwxte5s0.jpg.html]http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/9225A3EE-29E3-4483-A0C2-BD69D47C3635_zpsiwxte5s0.jpg[/URL]

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/C16D2E16-BEE3-4A44-9109-22B7633D896A_zpsmppmejgd.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/C16D2E16-BEE3-4A44-9109-22B7633D896A_zpsmppmejgd.jpg.html)

[Canadian818]

Erik, do you have any more pics of the brackets you welded in for the seats? Thanks

[ehansen007]

They are just 1" angle steel bracket needed on the outside rails only. As basic as it gets. :). The bummer is I forgot to put in the harness mounts!!

[Frank818]

Nice pedals.

[tmoretta]

Do the seats bolt right to the floor then? They look like they fit nice and low (more clearance for roll bar). Who sells those seats?

[ehansen007]

Well, I do. And yes, they bolt right to the floor and they are nice and low. I'm 6-1 and can't be using the stock seats. I've sold a few sets already to 818 members in fiberglass and carbon fiber. They are very well made. I'm considering making some bolt in brackets so there is no welding needed.

[wleehendrick]

I got the same seats from Erik and am happy with them. Erik, I'd be interested in a bolt on bracket kit if you put one together.

[RM1SepEx]

You can use a DC-DC converter to get 12v too. It's not acceptable to just pull 12 volts from a portion of the main pack.

http://www.thunderstruck-ev.com/dc-dc-converters-ev.html

[ehansen007]

Yup, however I have to use this one since I'm putting 170V into 12!

http://www.evwest.com/catalog/product_info.php?manufacturers_id=10&products_id=212&osCsid=rcesd7savfte1pmtl3ltjbndb1

[tmoretta]

I am interested too. Let us know.

[RM1SepEx]

Yup, however I have to use this one since I'm putting 170V into 12!

http://www.evwest.com/catalog/product_info.php?manufacturers_id=10&products_id=212&osCsid=rcesd7savfte1pmtl3ltjbndb1

that's a nice unit, my reverse trike only has 84 volts to draw the 12v circuit from...

[Speedy G]

Wow, nice build. I think I've read the entire thing like 3 times.

I'm wondering why you think the range of this thing is only 60 miles, if the tesla S with 60AH batteries claims at least 200 miles. I realize the Tesla has 2.5 times more voltage, but still... How do you calculate range? Is there a KWh number for a specific amount of miles? I'm surprised the thing weighed less than 800kg btw. In terms of weight, you could probably fit another 50 batteries. Nice job!

If Frank can't make the VR6 fit, an e-build is definitely my second choice. I'm investigating this alternative, but am wondering about an 6:1 gear reduction for a direct link. I'm considering a 12,000 RPM induction motor. Does anyone know if a Ford or Dana differential can be made to have a gear ratio of 6:1 or larger?

Speedy G

[ehansen007]

There's an EV calculator that can be used here.

http://www.evsource.com/battery_calculator.php

Now of course there are some tricks to increase mileage as with any car like hypermiling, tire pressure, etc however with this voltage and amperage, and the finished weight (projected at 2000 with driver). I would love to get more and I could have opted to run 180Ah but it would have double the cost of my pack. I'm hoping they will be able to fit 180Ah cells into the 100Ah boxes in the next few years and then make them cheaper as well. We'll see. The tesla system is quite different and yes there is a lot more voltage which is where they make it up. But I'm still not sure and will have to get a road test in to figure it out!


Vehicle Weight (lbs):2000lbs
Battery Type:Calb 100Ah LiFePo4
Cell Voltage Nominal (V) = 3.2
# of Cells = 50
Cell Weight (lbs) = 7
Pack Weight (lbs) = 357
Desired Range (miles): 65
Pack Voltage (V):160
Battery Ah rating (Ah):100
kWh = 16

[Rodster]

Hey Erik -
Just noticed your new project and need to say this is great, I can't wait to see this one on the street! You can generate some excitement by putting a Tesla logo somewhere.....

-wayne

[Gary Livingston]

There's an EV calculator that can be used here.

http://www.evsource.com/battery_calculator.php

Now of course there are some tricks to increase mileage as with any car like hypermiling, tire pressure, etc however with this voltage and amperage, and the finished weight (projected at 2000 with driver). I would love to get more and I could have opted to run 180Ah but it would have double the cost of my pack. I'm hoping they will be able to fit 180Ah cells into the 100Ah boxes in the next few years and then make them cheaper as well. We'll see. The tesla system is quite different and yes there is a lot more voltage which is where they make it up. But I'm still not sure and will have to get a road test in to figure it out!


Vehicle Weight (lbs):2000lbs
Battery Type:Calb 100Ah LiFePo4
Cell Voltage Nominal (V) = 3.2
# of Cells = 50
Cell Weight (lbs) = 7
Pack Weight (lbs) = 357
Desired Range (miles): 65
Pack Voltage (V):160
Battery Ah rating (Ah):100
kWh = 16

Luv luv luv ur build. Clean. Nice components selection.

16 kWh pack, depending how you drive... you should be able to reach 180 wh/m if its warm out and u baby it. That's about 89 miles . . if you take it to empty . . .which would be good. If you bottom balance and go BMS-less, it won't hurt much. . . except your pride. ;)

Regarding the performance though. . . don't expect to reach the numbers shown in your graph. The reason is the battery pack. I love CALB cells and the grey ones are stiffer than the blue ones . . however, fresh off charge they will settle out at about 3.34 vac or 167 pack volts. If you pull 1000 amps from them, you won't hold 100 volts I don't expect. 100 kw /746 = 134 HPe. It's the sag that gets you. That number may be optimistic even. None the less. . . love it. I would build the same car in a heartbeat.

Couple tidbids. . . you could loose the pb accessory battery and use a lithium one. Save some weight. ;) you could go without a battery if you only race, but on the street, I think it's a good choice.
Consider a couple Vicor batmod bricks to replace the dc/dc. Save some weight. ;)

Will u use a hydraulic pressure transducer to drive your regen?

Cheers,
Gary

[Jodie]

Luv luv luv ur build. Clean. Nice components selection.

Regarding the performance though. . . don't expect to reach the numbers shown in your graph. The reason is the battery pack. I love CALB cells and the grey ones are stiffer than the blue ones . . however, fresh off charge they will settle out at about 3.34 vac or 167 pack volts. If you pull 1000 amps from them, you won't hold 100 volts I don't expect. 100 kw /746 = 134 HPe. It's the sag that gets you. That number may be optimistic even. None the less. . . love it. I would build the same car in a heartbeat.


The CA##FI cells have been proven to sag to 16% at 12C after 15 seconds.*
1200A = 140V.
It is the sag that gets you, that why these cell kick ***!
*http://evtv.me/2012/09/battery-joy-and-the-car-guy/

[jmccabe]

I first saw your build on EvWest's Facebook page. I'm also a happy customer building a FFR Roadster. EV of course ! My build has been picking up speed after some long delays. Cant wait to get back to Laguna Seca and beat that darn m3 BMW :)

Jeff

http://www.ffcars.com/forums/17-factory-five-roadsters/246129-let-my-electric-roadster-begin-4.html

[ehansen007]

Luv luv luv ur build. Clean. Nice components selection.

16 kWh pack, depending how you drive... you should be able to reach 180 wh/m if its warm out and u baby it. That's about 89 miles . . if you take it to empty . . .which would be good. If you bottom balance and go BMS-less, it won't hurt much. . . except your pride. ;)

Regarding the performance though. . . don't expect to reach the numbers shown in your graph. The reason is the battery pack. I love CALB cells and the grey ones are stiffer than the blue ones . . however, fresh off charge they will settle out at about 3.34 vac or 167 pack volts. If you pull 1000 amps from them, you won't hold 100 volts I don't expect. 100 kw /746 = 134 HPe. It's the sag that gets you. That number may be optimistic even.

Cheers,
Gary

Thanks Gary. Thus far in the build I've managed to succumb to only a few rebuttals regarding this power plant so I feel pretty fortunate. This is because i have selected a team of three and they are : a battery expert, an exceptional engineer, and a guy who is both and has won at pikes peek in an EV. They are all being conservative however if they are saying we can get there, I'm going to believe them.

[ehansen007]

McCabe I do remember reading this post a while back. It looks awesome! Hopefully l'll see you at Laguna seca!

Thanks for chiming in Jodie. I've had to use Jacks video a few times to check the math!

[Gary Livingston]

Thanks Gary. Thus far in the build I've managed to succumb to only a few rebuttals regarding this power plant so I feel pretty fortunate. This is because i have selected a team of three and they are : a battery expert, an exceptional engineer, and a guy who is both and has won at pikes peek in an EV. They are all being conservative however if they are saying we can get there, I'm going to believe them.

Oh, don't get me wrong, . . I think you have an excellent selection of components. EV West is definitely outstanding. As for the C rate vs voltage drop, it will depend a lot on the temp of the cells. I think Damien first tested them and did a youtube on it. yup. . . here it is...http://www.youtube.com/watch?v=lyYfFeWwd9I with the 180 ah cell, it dropped to 2.0 volts at 12C, close to 40% voltage. Pretty much what I stated. Now, his temps were lower and if I recall, it was bloody hot when Jack did his testing.... and had been charging them 40ah cells pretty good before also. I can attest to the cold impacting C rate... lol, from up her in Canada it's been -25C pretty steady and I can't get much out of my CALB pack at these temps...lol Once you warm them up, they will stiffen up nicely. Unless there is a difference between the smaller cells and the bigger cells. . . I dunno. AT any rate, the grey's are definitely an awesome cell (for a range battery).

[ehansen007]

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/A737F496-53CC-4DCB-84DE-4A4803974D26_zps23iksngz.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/A737F496-53CC-4DCB-84DE-4A4803974D26_zps23iksngz.jpg.html)

I'm using a 12 component harness from EZ to wire this car.

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/59f09839-2fe5-4751-8139-69be87533f41_zps2f403f90.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/59f09839-2fe5-4751-8139-69be87533f41_zps2f403f90.jpg.html)

The master went right to work

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/69E7D69D-4F52-4FFF-A7D2-873E1E13D906_zpsa6oywg2t.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/69E7D69D-4F52-4FFF-A7D2-873E1E13D906_zpsa6oywg2t.jpg.html)

A little wiring work.

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/3021B344-55F0-4667-A03C-E61CE234923B_zpstgtgcwlz.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/3021B344-55F0-4667-A03C-E61CE234923B_zpstgtgcwlz.jpg.html)

Michael is the 12V master. I little bummed I didn't do it myself but with an electric car I need it done right...the first time!!!

[ehansen007]

Oh, don't get me wrong, . . I think you have an excellent selection of components. EV West is definitely outstanding. As for the C rate vs voltage drop, it will depend a lot on the temp of the cells. I think Damien first tested them and did a youtube on it. yup. . . here it is...http://www.youtube.com/watch?v=lyYfFeWwd9I with the 180 ah cell, it dropped to 2.0 volts at 12C, close to 40% voltage. Pretty much what I stated. Now, his temps were lower and if I recall, it was bloody hot when Jack did his testing.... and had been charging them 40ah cells pretty good before also. I can attest to the cold impacting C rate... lol, from up her in Canada it's been -25C pretty steady and I can't get much out of my CALB pack at these temps...lol Once you warm them up, they will stiffen up nicely. Unless there is a difference between the smaller cells and the bigger cells. . . I dunno. AT any rate, the grey's are definitely an awesome cell (for a range battery).

That Youtube test was also pulling 2000A when it went to 2.0V. Did you watch the rest when he went to 1500 and only dropped to 2.5V. I'll be maxing out at 1000A with a smaller battery at 12C we're predicting 10% loss. We've built in a couple extra cells to get us to 160V and 10% x 160 is 16V. Subtract that from our pack and you get 144V.....which is.....wait for it.....the controller voltage! :) But still, you never know.


Here's what I'm dealing with for Temps.
http://pics2.city-data.com/w1q/lhaq2696.png

[Gary Livingston]

That Youtube test was also pulling 2000A when it went to 2.0V. Did you watch the rest when he went to 1500 and only dropped to 2.5V. I'll be maxing out at 1000A with a smaller battery at 12C we're predicting 10% loss. We've built in a couple extra cells to get us to 160V and 10% x 160 is 16V. Subtract that from our pack and you get 144V.....which is.....wait for it.....the controller voltage! :) But still, you never know.

Hey. Ya, I watched the whole video. And I've been watching Jacks videos since Matt worked there back in the day. I don't watch them any more coz I just don't have the time. I've even drank Jacks awesome home made whiskey in his garage. Lol. That was the first EVCCON. I LOVE YOUR BUILD. I'm going to do one, electric as well. I can't think of much I would change from what you're doing. I have done a few DC motor builds and I also own a Chevy Volt I really love the regen. I have 13" motor and a Shiva in my truck now. The Shiva is the same 3000 amp (1600 hp capable) controller EV West has in their car. In fact, interestingly enough, the SN on their Shiva is 001 I believe and I have 002. I actually funded the first one and Evnetics asked me if I would mind letting mine go to EV West due to some publicity they were prepping for. I didn't mind, I wasn't quite ready. So, tell the boys there they owe me a spin and a tour around that awesome shop when I get down that way. Lol. Will u use a hyd pressure transducer to drive your regen?

Ya, as for the amperage Damien was pulling, he was using 180 ah cell, so 2000 amps is just over 11C with a 38% voltage drop. The 1500 amps on that cell is 8.3 C with about 22% drop. Temperature does make a big difference. Carbon actually drops in resistance as it gets hotter. I have a pack of A123 32157's and they will give up 65 C when they are warmed up. There may be some differences also in the size of the conductors inside the smaller CA40FI vs the CA180FI so perhaps it will do a bit bitter than the larger cells based on C rate

[Gary Livingston]

That Youtube test was also pulling 2000A when it went to 2.0V. Did you watch the rest when he went to 1500 and only dropped to 2.5V. I'll be maxing out at 1000A with a smaller battery at 12C we're predicting 10% loss. We've built in a couple extra cells to get us to 160V and 10% x 160 is 16V. Subtract that from our pack and you get 144V.....which is.....wait for it.....the controller voltage! :) But still, you never know.

Hey. Ya, I watched the whole video. And I've been watching Jacks videos since Matt worked there back in the day. I don't watch them any more coz I just don't have the time. I've even drank Jacks awesome home made whiskey in his garage. Lol. That was the first EVCCON. I LOVE YOUR BUILD. I'm going to do one, electric as well. I can't think of much I would change from what you're doing. I have done a few DC motor builds and I also own a Chevy Volt I really love the regen. I have 13" motor and a Shiva in my truck now. The Shiva is the same 3000 amp (1600 hp capable) controller EV West has in their car. In fact, interestingly enough, the SN on their Shiva is 001 I believe and I have 002. I actually funded the first one and Evnetics asked me if I would mind letting mine go to EV West due to some publicity they were prepping for. I didn't mind, I wasn't quite ready. So, tell the boys there they owe me a spin and a tour around that awesome shop when I get down that way. Lol. Will u use a hyd pressure transducer to drive your regen?

Ya, as for the amperage Damien was pulling, he was using 180 ah cell, so 2000 amps is just over 11C with a 38% voltage drop. The 1500 amps on that cell is 8.3 C with about 22% drop. Temperature does make a big difference. Carbon actually drops in resistance as it gets hotter. I have a pack of A123 32157's and they will give up 65 C when they are warmed up. There may be some differences also in the size of the conductors inside the smaller CA40FI vs the CA180FI so perhaps it will do a bit bitter than the larger cells based on C rate. That's just a wild a$$ guess tho with no data to support.

I actually have enough components now to do an 818 electric, but it would be DC drive motor. It would have much more torque, but no regen. I'd really like to do it AC. I just wish the Curtis 8501 did higher voltage.

Oh, yes, question, I noticed different options when ordering, (turbo etc) does it matter for the EV build and which did u pick? I don't know much about the Subaru componentry yet, but I'm a-learnin'.

Had to re-post. On my hand held and it's brutal. Lost some content.

[ehansen007]

It was a hard choice between AC and DC. Even Michael and Matt were disagreeing! On one hand you have a torque monster that would just crush about anything and with that you had to change brushes and had a motor that wasn't as civil. On the other you had smooth power, no brushes and regen. Really the new vs. the old tech. As Bob put it, how many new cars do you see with a DC motor in it? I understand if you are doing DC then a Soliton 1 with a Warp 9 or 11 is the way to go. There is a big price difference too however what you save in motor you pay more for in batteries since you run higher voltage. I'm just a rookie though and haven't driven or built either to this point!

For the chassis, no it doesn't matter which one you pick. Just pick one and go man! :) You could build a sweet DC powered one with little to no modifications to the frame.

[Gary Livingston]

It was a hard choice between AC and DC. Even Michael and Matt were disagreeing! On one hand you have a torque monster that would just crush about anything and with that you had to change brushes and had a motor that wasn't as civil. On the other you had smooth power, no brushes and regen. Really the new vs. the old tech. As Bob put it, how many new cars do you see with a DC motor in it? I understand if you are doing DC then a Soliton 1 with a Warp 9 or 11 is the way to go. There is a big price difference too however what you save in motor you pay more for in batteries since you run higher voltage. I'm just a rookie though and haven't driven or built either to this point!

For the chassis, no it doesn't matter which one you pick. Just pick one and go man! :) You could build a sweet DC powered one with little to no modifications to the frame.

I like the AC route also. All electric motors are really AC motors. . . even the "DC" ones. The main difference is that commutation happens in the controller as opposed to the commutator (with brushes) on the "DC motors". I don't think there is a real difference in the "power" related to being smooth, since power is power but I know what u mean. . .I think the regen has a nicer feel if done right. Thats why I asked how you were driving yours. I do have a Soliton1 also and will do 1000 amps (battery and motor) up to 340 volts. Thing is, if you are only using one motor, u have to limit it to 200 max and even that requires some tweaking. If you use two motors, then you can take advantage of the higher voltage and if your pack is stiff enough, get close to that 400 hp rating. Sag always detracts. I have 4 different controllers right from 500 amps right up to 3000 amps. I also have 4 different motors, 6.7", 9", 11" and a 13". I don't buy Warp motors though. . . since you can modify fork truck motors to work just as well if you know what to look for and what to do to them. In fact some would argue that the GE motors are even better. The Warp motors all started off as fork lift motors anyways. As for voltage of the pack, it's not really true about needing higher voltage for DC. In fact, AC motor systems typically go much higher in voltage than DC drive systems. The only problem is that the ones available for DIY's like us, (means affordable) they aren't so high in voltage. The OEM's all use AC as you say and higher voltage at that. 300 to 500 or even 600 isn't unusual. Battery costs are similar since you pay for kwh whether it be lower voltage and higher Ah or vice versa.
I could do a 1000 hp DC set up in an 818 with ridiculous torque but, I don't think it would be as practical as what you are doing. It would save me a bunch of money though. I just may have to sell some of my toys. :)

Sorry for hijacking your thread. I have been reading a lot about the Subaru drive train. . . trying to decide what is best. That big 5 speed transaxle seems to be overkill. You may not use all the gears. I had a 5 speed manual in my first build and I would start in 2nd gear, shift to 4th and unless I went on a super highway I didn't use 5th either. Do you know how much that tranny weighs? I can't seem to find a weight on it. Looking at the dual AC35 set up, it is likely the easiest way to go. If I did a DC drive, I would like just use a 2 speed and a separate differential. . . like maybe the one out of the WRX rear . . if I could find one strong enough.

Do you know how much the chasis weighs without any drivetrain? What about the gas engine? Just wondering how much "electrical stuff" I can pack in before exceeding the weight of the ICE version.

[Wayne Presley]

Do you know how much that tranny weighs? I can't seem to find a weight on it.

Weighs 112 lbs right out of the car and 92 lbs with center diff/transfer gears removed

[Gary Livingston]

Weighs 112 lbs right out of the car and 92 lbs with center diff/transfer gears removed

Oh! thanks very much.:) I thought it might be heavier than that.... I did find in one other thread, the weight of some things. Motor and trans totalling about 450 lbs. approx.

[ehansen007]

Spent last Saturday wiring and more wiring!

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/72B2BC88-D02D-4C16-9713-11FE1627902B_zpsb9ykgocr.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/72B2BC88-D02D-4C16-9713-11FE1627902B_zpsb9ykgocr.jpg.html)
Getting the controllers wired in tandem as well as running all wires for gauges, ignition, throttle, etc to the front.

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/999E5B7B-BA6F-4343-92F9-49568DBB5657_zpshmocauem.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/999E5B7B-BA6F-4343-92F9-49568DBB5657_zpshmocauem.jpg.html)
Then I went to work on wiring the controllers to the motors. This was COOL. I learned how to use a HYDRAULIC crimper to fasten leads onto 2/0 wire! This was a process and because these cables stand out like Carrot Top in Japan you work hard to ensure they are aesthetically appealing.

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/C2CBC583-FC1C-4C4C-BE74-23A47EA4A34A_zps8dqfzcmp.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/C2CBC583-FC1C-4C4C-BE74-23A47EA4A34A_zps8dqfzcmp.jpg.html)
These cables are husky too so you have to think before you route. Shrink wrap is key! There will be 150V going through these at 500Amps so crossing of the streams could be "bad" :) All high voltage wire in this car is designated as orange to include conduit.

[ehansen007]

Spit balling here. Because I won't be running a radiator in the front and won't need the hole, I plan on covering it up and creating a more visually appealing nose scheme to bring in the headlights. I'm a fan of the large black fascia of todays cars whether it's functional or not! :cool:

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/63F43F5C-212D-429C-975A-B4A7C05A62FD_zpsa7nhhsmt.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/63F43F5C-212D-429C-975A-B4A7C05A62FD_zpsa7nhhsmt.jpg.html)

[Bob_n_Cincy]

Great job Erik,
My 818S_E has been on hold while I work on the wiring diet for the 818S_ICE.
I like your Nose, I will be blocking off mine also. Remember flat black doesn't reflect police laser's.
A couple of suggestions,
Add some grommet edging on the CF motor cover. That stuff is conductive and will cut right through wire insulation.
I would add some nomex 410 paper between motor distribution block post. They are closer than I like.
Can't wait to see an electric version on the road.
Bob

[Oppenheimer]

...Remember flat black doesn't reflect police laser's.

But the headlights still do reflect, all too well. Well enough that they are all that is needed to get a reading.

[ehansen007]

Speaking of headlights......

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/610903EF-680A-4E35-8B84-5D3F97A72FDA_zpsuj0tdj5p.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/610903EF-680A-4E35-8B84-5D3F97A72FDA_zpsuj0tdj5p.jpg.html)

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/F176C22C-4365-4548-BDD0-141667C6AD13_zpss0lbg0qu.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/F176C22C-4365-4548-BDD0-141667C6AD13_zpss0lbg0qu.jpg.html)

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/F43DA143-8CB6-4880-B93C-1A555AC23B91_zpsxkmglzpw.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/F43DA143-8CB6-4880-B93C-1A555AC23B91_zpsxkmglzpw.jpg.html)

[wleehendrick]

Speaking of headlights......

:cool:

[Frank818]

HIDs. Nice. I got the normal ones (won't drive much at night) with halos, not the LED bar. Gives me an idea how mines will look, pretty neat.

[Samiam1017]

Are they an aftermarket headlight. Or did you modify the lights that came with the kit?

[Xusia]

Aftermarket. Look at the blinker. :)

[ehansen007]

Our project manager is testing for electricity....getting close....

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/6C06ED48-21E2-4DB3-A692-EA2F241F2415_zpsvy7rbxu0.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/6C06ED48-21E2-4DB3-A692-EA2F241F2415_zpsvy7rbxu0.jpg.html)

[metalmaker12]

Lol love it!!!

[David Hodgkins]

How did you get that shot?!?

[Frank818]

That's easy with today's camera's/phone's burst mode. :)

It really is a shot to remember.

[jayguy]

That's awesome!

[ehansen007]

Video removed. More video coming soon!

[longislandwrx]

Nice! looks like you need some more lock and faster hands :D

[Olli]

Cool video!

Olli

[Bob_n_Cincy]

Great job Erik, and nice video.
It looks the low center of gravity is keeping the car very flat.
Do you know how much current you were pulling during you test drive?
Bob

[Frank818]

Were you producing movie trailers sometime in a past life? :)

[wleehendrick]

Need Moar opposite lock!

Great vid, but you forgot the rating :p

26684

[ehansen007]

Hey Bob, Not sure how much current yet. We need to get the Xantrex hooked up. We had the motor controller gauge going and we noticed that we were dropping voltage and we brought it back immediately. We had two cells that were below 3V and one was at 2.6 so it's either bad or just lower than the others. We charged the two back up to match the others at 3.10avg and we'll drive it again. If they hold we'll bottom balance from there and then charge them up! Unfortunately we didn't get the video of doing donuts out in the street.

[Bob_n_Cincy]

If your at 3.10 you are already at the bottom balance starting point.
Which BMS are you using?
Bob

[wallace18]

Awesome!!!!!!!!!

[Rasmus]

Vroom vroom!

...err....

..ahh..

I mean... Wiii - wiiiiiiiiiiiiii!

Looking good, EH. Looking good.

[metalmaker12]

Wow your the man!!!

[Frank818]

There seems to be quite some torque in that thing! And the sound is better than I expected, maybe the tranny sound for some of what we can hear?

[rtz]

If your at 3.10 you are already at the bottom balance starting point.
Which BMS are you using?
Bob

It may end up we don't need a BMS if one doesn't over charge or under discharge. Read page 6 and 7 if you haven't already: http://media3.ev-tv.me/cellcare.pdf

[ehansen007]

It may end up we don't need a BMS if one doesn't over charge or under discharge. Read page 6 and 7 if you haven't already: http://media3.ev-tv.me/cellcare.pdf

Yup that's our philosophy. Thanks for posting. And of course, as with any automotive power discussion we realize there are varying opinions. EV buffs can be as passionate as any group when it comes discussions like this and the BMS discussion is a big one. In this case, the grey cells are fairly new and we have to go with what has been proven to work to this point. The good news is that in this world, more now then ever before, development is progressing rapidly in battery technology. Hope you enjoy the videos and progress to this point.

[rtz]

What's your to-do list looking like?

[ehansen007]

Get the car home this week.

1. Weld in the harness tabs and install the seats
2. Get the windshield frame painted (maybe dip it?) and install glass
3. Get working on the body
4. Interior with center console to house 10" ASUS tablet

I'll hopefully have it ready for the HB show. I won't be painting it yet so I won't be doing a ton of bodywork. Mostly just touch up.

[Gary Livingston]

Nice Job Eric! Woohoo another EV Grin. :) Looks good. How did it feel? Looks like you are pushing it pretty good there after a few laps...lol I really enjoyed that. :)

I concur with the No-BMS direction. I'm not totally against some types of BMS's for certain chemistries. That said, I've been running my CALB's for several years now sans BMS. I've had no problem with balance. I Bottom balanced and under charge. Jack is right. You can always add a split pack monitor if you want. (Compares two pack halves to each other) This will give you early warning. Undercharging costs almost nothing in range. . . there is almost no capacity above 3.5 volts on LiFePo4 anyways.

Way to go man! Git er done!

[ehansen007]

Thanks man, the car feels quick at half charge so I'm optimistic of a full charge! I was able to do donuts pretty easily. Didn't get it on video though.

[blueoval_bowtie_guy]

No picture - it didn't happen!

[Triathletedave]

Get the car home this week.

1. Weld in the harness tabs and install the seats
2. Get the windshield frame painted (maybe dip it?) and install glass
3. Get working on the body
4. Interior with center console to house 10" ASUS tablet

I'll hopefully have it ready for the HB show. I won't be painting it yet so I won't be doing a ton of bodywork. Mostly just touch up.

Would love to see pics of the console with the tablet mount. Very interesting idea.

[esff32]

That is sooo cool. I love how all you hear are the tires squealing as the car goes around the building. Looks like its pretty torquey. Awesome Erik.

[first time builder]

Best part of EV no rear main leak. !

Kenny

[Gary Livingston]

Best part of EV no rear main leak. !

Kenny

Other good parts of EV.
- not having to wait for gas tank to fill in the freezin cold.
- instant heat
- no brake jobs (with regen)
- no oil changes... practically no maintenance at all... no belts, hoses, exhaust systems, fuel systems etc .
- low end torque. 150 hp competes with 300+ ice hp.
- the best of all..... "saving the world" :o

Sorry, Kenny. . . couldn't resist... :)

[ehansen007]

True, true. Some recent work includes a nifty little motor stabilizer (mostly for looks but it should work) as well as the harness tabs and floor

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/89EE9D96-3E71-4735-AC20-B5FC9F4D49C7_zpsymds3xat.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/89EE9D96-3E71-4735-AC20-B5FC9F4D49C7_zpsymds3xat.jpg.html)

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/505D239E-1E5B-4341-86DE-8DD2D3C4C070_zps7sfdft6p.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/505D239E-1E5B-4341-86DE-8DD2D3C4C070_zps7sfdft6p.jpg.html)

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/72C81898-C7B7-4A6B-89C0-2672F42A6209_zpshymv9j11.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/72C81898-C7B7-4A6B-89C0-2672F42A6209_zpshymv9j11.jpg.html)

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/E25329DA-E2A7-44C2-9EBE-783FDE77C5D8_zpsqaizlani.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/E25329DA-E2A7-44C2-9EBE-783FDE77C5D8_zpsqaizlani.jpg.html)

[ehansen007]

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/D0BD992A-B389-4340-8943-F81FF4152543_zpsb9uojz5a.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/D0BD992A-B389-4340-8943-F81FF4152543_zpsb9uojz5a.jpg.html)

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/154E9F2E-9DEA-41ED-8E40-CC18018BD211_zpspwyypdop.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/154E9F2E-9DEA-41ED-8E40-CC18018BD211_zpspwyypdop.jpg.html)

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/CF05F01F-968F-4076-A00A-13441AA6DEB2_zpsjkf4xphg.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/CF05F01F-968F-4076-A00A-13441AA6DEB2_zpsjkf4xphg.jpg.html)
http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/61DD79FD-8E5B-4899-9516-6BF6617DAD72_zpsrv52rnqj.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/61DD79FD-8E5B-4899-9516-6BF6617DAD72_zpsrv52rnqj.jpg.html)

I had to reroute the ebrake and create a custom set up. You can barely make it out here. But it works pretty well.

[Gary Livingston]

Dang that motor looks sweet with the carbon fiber wrap. :o

[Frank818]

I agree it's really awesome.

[flynntuna]

Can't wait to see your amazing work at HB next month! You are setting the bar at a very high level.

[ehansen007]

Thanks dudes. My focus is going to be on interior for now and I'll be showing it at HB with no body. I'm in between FFR carpet kit and doing it myself. It's not that much coverage right? Door panels should be fun.

[metalmaker12]

Everything looks really amazing.... Except that bead! J/k it's not to bad

[Frank818]

Hey Erik!

Congrats for being on the Factory Five News March 2014 email we just got in the mail!

[ehansen007]

Thanks frank!

[windrider991]

Eirk, this is simply a great thread, and you and the others open discussions are really educational, and inspiring! The first time i saw the 818, my intial thought was how great an EV it would be. I simply cannot wait to watch the 818E's whip all comers! Thanks again to all those contributors to this thread and to FFR for making such a great kit available!

[ehansen007]

Fabbing up a harness bar. While I could have wrapped them around the square bar, I felt it was a bit too low for me and I couldn't just let those tabs with the holes go unused! :) I cleaned up the welds and took it to powdercoat yesterday. What do you think?

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/186BEFA5-7FCD-478B-8872-B4BB972BF63E_zpsnrylz0mq.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/186BEFA5-7FCD-478B-8872-B4BB972BF63E_zpsnrylz0mq.jpg.html)

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/CFB824C7-9860-482B-8A91-0D96C81F7A78_zps1xpe34vq.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/CFB824C7-9860-482B-8A91-0D96C81F7A78_zps1xpe34vq.jpg.html)

http://i897.photobucket.com/albums/ac177/ehansen007/818/818%20BUILD/8B3EFEA6-A960-4F92-A76D-CA7D403DB44A_zpspaiblbhp.jpg (http://s897.photobucket.com/user/ehansen007/media/818/818%20BUILD/8B3EFEA6-A960-4F92-A76D-CA7D403DB44A_zpspaiblbhp.jpg.html)

[wleehendrick]

Hey Erik, looks good. As you know, I have the same seats, but the way I mounted mine, that would be too high, so I'm using the square bar. Can't wait to see it finished at HB.

Lee

[Canadian818]

How's the leg room? My head rests touch the roll bar cross brace, looks like yours is 3-4" ahead.

[07FIREBLADE]

Where did you get the weld in bungs and eyebolts? And what size? I was going to make the same thing shortly.

[ehansen007]

Yeah. My seats are right in the seat area and with my battery boxes behind I put the bolts in the middle hole front and rear on the seats so it's a little more upright than I wanted but oh well. But leg room is fine. Sounds like you got yours back there with that Boyd tank! I got the threaded ends from my local welding shop but you can get them from McMaster.com. I was going to make a few more actually and sell them complete and powdercoated.