Tuesday, July 26, 2016

Back to battery boxes.

Fitting all the batteries in without having exact dimensions on the motorbay and under the contoured rear seats is a challenge.  Everything is still subject to change, but here is where we are at.

1/3 of the original pack getting ready for disassembly.
We have learned that the individual modules need to be kept under compression during cycling to maximize longevity.  These modules should be squeezed to 1.33" per module.

Oui this is going to be fun to rewire...
We have not figured out why, but all black leads go to the intermediate connectors, and all purple leads to actual power connections.  The plates are different sizes so this end would be tough to do wrong.  We mapped the connector to the module connection location expecting the pins in the connector to be of minimum potential to the next pin.  That is not what we found.

Any suggestions on materials to use when we reconfigure to protect all the connections from shorting?

Rear battery box, 26 modules.
The cursor points to were we hope the contactor will fit.

Front boxes, 22 modules
The cursor points to where we hope to place the front contactor, heater relay and pre-charge circuit.
We are not happy with this yet, and are considering moving the DMOC forward to get another vertical stack of 12 above the motor.  We would then use the space over the DMOC for the contactors etc.

DMOC adapter test box made.

We have made a box to interface with the DMOC for trouble shooting.  A "REAL" version can be found at http://www.wolftronix.com/store.html  The real version has two circuit boards in it and is very "clean".

Our version is a little more home grown from scrap parts, a lot of little wires, several hours, and  just a choice word or two.  Labels have yet to be added.

Trust me, the layout is totally logical ;)  Can you tell we are making this in a house that had kids?  Popsicle sticks can do anything.

Motor mounted and delay explained

A little delay, but we have the motor, transmission, and DMOC mounted in the motorbay!

We had two incidents delay our progress for a little bit.  First a storm came through and took out multiple healthy trees in the neighborhood.  Our TV antenna was still attached to the house and reception was great for a distant PBS channel.

A little reinforcement in the attic with 4x4's.
The antenna may get folded in the future, but the attic and siding will stay.

Our next "quick" project was on the main car.  The trailer tire valve cut 1.5 miles from home with a load of pavers onboard.  I was offline at the time and a large portion of the load was put in the family station wagon.  The rear springs and jounce stops were not happy.  The springs took a permanent squat.  Just get new springs right?  We often have 4 and 5 in the car with gear in back so I decided to look for a slightly stiffer spring.  The VW springs are weight classified and given color codes.  The actual spring stiffness values are not listed.  Our code was 1 green dot, 2 brown dots "P".  Arghhh.  After several weeks I found a listing on a Russian website :) yeah!

 I went to the local recycle yard and drove across the scale.  Front axles 2020lbs, Rear axles 1440lbs, whole car 3460lbs, with a 143lb driver.  We now have new jounce stops and the 1 green/2 blue "AD" springs installed, the intermediate "T" springs were not available.  The back of the car came up an inch and looks much happier now.  Amazing how the eye can see an inch.  FYI, the 1BE springs are about an inch shorter than the 1BA springs.  Anyone need a set of used 1BA with a 1" set is them?

This has been a good exercise for us as the GOLF will need new springs to deal with the added battery weight.  I have not found the above charts for the GOLF spring colors and weights.  ANYONE have it?

Tuesday, July 5, 2016

Aw nuts

Well, we almost got it in...

Transmission lowered onto the motor, AREN"T engine hoists nice...  Slipped right together! 
On the hoist and waiting for help and a motor mounting plate.
A little welding touch up action on the motor mounting plate to help me sleep better.
A long time friend of my son that has recently taken several welding classes came over to touch up a part and teach my son a first lesson in welding.  HOT!  He gave me some refresher comments too.  P.S. auto tint welding masks are awesome!
Some post weld heat treatment to account for weld pull during cooling.

Aw nuts, the original VW mounting bolts are M12x1.5 not M12x1.75 like all the other bolts on the engine.  A quick trip to the hardware store to get the right nuts and then mounting the transmission and motor will be complete.  If you look hard you can see the halfshafts are already connected back on.

Friday, July 1, 2016

Welding and machining complete of motor mounting hardware.

Motor mounting plate welded and bolted.  Still needs some grinding on the weld to clean it up.

Spline coupler welded to the old clutch plate, mounted, bolted and thread locked to the motor.  The welding turned out better than expected the second time.  (There is a story here, check orientation before welding...)

Adapter plate plate ready to receive the motor.

We will be putting the motor in for the second and last time this weekend!  By Monday turning the motor will turn the wheels!  Maybe even a video of the install.  Anyone out there have a favorite free software for creating time-lapse videos coming off a Samsung galaxy running cyanogenmod?