Originally Posted by ElectriCar
I met a guy tonight who turned me on to some things. He has to me a lofty goal stated above. He's running the Advanced FB1-4001A with Curtis 1231 controller. Here's what he's doing or has done with the truck currently stripped to the frame.
- Cut holes in the framing where he says it won't affect the structural integrity.
- Will use ALL TITANIUM bolts and nuts to put it together.
- Front hubs remade from aircraft aluminum.
- Aluminum Motor mount
- Composite leaf springs
- Carbon Fiber inner fenders
- Carbon Fiber bed
- Light weight brake parts, maybe ceramic rotors.
- Light weight no vacuum assist master cylinder - Says it will be easy to brake too.
- Delete vacuum pump due to master cylinder selection
There may be more stuff but I can't think of any now. I did turn him on to this site though so maybe he'll chime in. He's worked with race cars for years so he knows a lot of stuff because of that.
I am very interested in how to swap out power brake master for purely mechanical... to avoid the whole vacuum pump and switch thing would save weight, complexity, time and space under the hood!
The rest of this is sounding like the (many) 'weight weenies' in the bike racing world where grams matter when you are looking for an extra .5% of acceleration. The thing is that exotic materials drive cost up rapidly, and 'lightening' structural members is rarely a good idea. Machining cool AL parts from billet gets super expensive unless you happen to own/work in a machine shop with access to 'scrap' for free.
most of us can probably drop 50 pounds out of the car by lightening the OCCUPANTS and carrying less crap around in the vehicle.
I have made a decision to not lug around spare tire and jack in my EV; I'll never be very far from home!
I am still interested in the high 'bang for the buck' items though. For instance:
- using AL instead of steel for battery rack edges
- swapping OEM seats for light racing seats
- carbon-fiber/fiberglass hood, fenders if available
- swapping flat glass with Lexan if possible
and then doing the same for the 'major' aero mods like:
- blocking grill
- smooth belly-pan
- consider backup cameras instead of mirrors... legal?