DIY Electric Car Forums > EV Conversions and Builds > All EV Conversions and Builds

jackbauer · #**121** 01-22-2010, 03:22 PM

Yeh the old adapter was more "JCB" than "BMW"

. Anyway installed the torque rod and all the control gear back in place and hooked up. The difference is phenomenal! With the old coupler even at low rpm in neutral , it made a rattling sound. Now it makes no noise at all and no vibration even through the gear stick. I gave it full throttle with no shunt field (only 24v still waiting on my new batts) and got it up to 1600rpm. Thing sounded like a gas turbine winding up!! All was missing was the tick tick tick sound of the igniters

I can definatly advise anyone considering a jaw coupler to avoid it. Well worth the time and effort of removing everything to fit the new adapter / coupler.

In fact it was so quiet that I detected a rumbling from the diff. Got under the car with a brick on the accelerator to narrow it down. Long story short the diff had less than a cup of oil in it due to an incorrectly fitted filler plug. I'd guess someone checked the level at some point and never retightened the filler. Ordered some oil. Hope nothing is damaged!

Now i gotta get back to finishing up the charger and getting it and the batts installed next week.

jackbauer · #**122** 01-24-2010, 09:52 AM

Well with the car back together i decided to finish up the charger. Just some metalwork. Naturally i was short one bolt!!! Will hopefully be installing the charger and batteries this week. Also like to say once more a special thanks to Simon for making the design available. I'll fully document the isolation and igbt drive mods i made if anyone is interested.

Dave Koller · #**123** 01-24-2010, 11:48 PM

Had the same problem welding my mount - use angle pieces and went SLOW..
If I warped it, the trans axle would be off ! Yours looks nice Jack - been watching that charger build... Use Arduino's a lot with LCD screens...

jackbauer · #**124** 01-25-2010, 02:37 PM

Nice work there dave like the adapter. Upgraded the igbt drive section in the controller today to reduce switching losses. Also began preparing for charger install and ran two conduits from the boot to the engine compartment for the rear batteries. Few vids:
http://www.youtube.com/watch?v=m04KxFPNqZA
http://www.youtube.com/watch?v=99CjYwGOFNk

Dave Koller · #**125** 01-25-2010, 03:14 PM

Jack

Have looked at a few of your videos BUT I am in the middle of nowhere and have dialup

Takes about 1 1/2 hours to download one

- but I enjoy them... Looked at part of the cutting hay one last night before it crashed - lol I cut hay at my farm so it caught my eye.....can't believe it crawled on those batteries.... I will look at one of the posts tonight .

jackbauer · #**126** 01-25-2010, 03:24 PM

Glad you enjoy them dave! Thats the whole point. I was very surprised at how well it performed on those two batts. Gave me a real boost. Its funny on the day when i started veering into the ditch the phrase "cutting hay" popped into my head. Its a line from an old 70's sci fi book called Fadeout by Patrick Tilley. Very obscure i know

Just shows i have a messed up brain!

Woodsmith · #**127** 01-26-2010, 03:25 PM

That new set up sounds really sweet, well worth the effort.

It is interesting to see the revs drop from neutral when the higher gears are selected. Shows the drag in the gearbox.

jackbauer · #**128** 01-28-2010, 12:36 PM

Battery time! Today i received the first 4 of my traction batteries. Odyssey PC2150 105ah agm. This first batch will be installed on a rack behind the rear seat. Sorry for the bad pics only had phone camera.