[brian_]

Would it be viable to build a frame from front mounts to tail mound to replicate what the original distribution might have been?

It is a good idea structurally to use original mount locations, but the mount locations don't determine the weight distribution.

 

[jclars]

I got back to basics that I can understand. Building blocks!

And I answered my above question directed at Lars. With each block duplicating a single CALB 230Ah battery cell, I was able to try different orientations in situ. Very helpful for my mind.

The blocks are supported off the frame rail and none extend beyond the sub frame with motor mount.

In this layout I can get 15 cells, leaving 9 on the drivers where the steering column interferes. I could also consider a shelf off the firewall if the driver side row interferes with my desired motor view.

Have at it!

 

[remy_martian]

Don't understand why you want to experience the equivalent if a 400lb passenger riding with you all the time.

If you're happy carrying that small of a pack, knock that top row off and put it over the motor as one single-level box. It'll lower the c.g. so it doesn't handle like a bread truck.

What you're doing with this latest layout is equivalent to jacking up the original engine on 250mm motor mount spacers, and shifting it to the passenger side of the compartment.

Then pile your other stuff, which you were going to bolt to the firewall, on top of that since it's all low mass components.

Your car spends 99.99% of its time with the hood closed, and an electric motor is as exciting as looking at the alternator on an ICE car. Maybe put Christmas lights on the battery box if you want EV bling when you open the hood 😛

EV's are alll about the driving experience...the kudos from others come from the passenger/driver seat, not when it's parked. Carrying over ICE biases to an EV conversion will cost you and make you miserable.

 

[jclars]

Well stated! However, it is only 150 lb on that side. Not a 400 lb fat lady. Is that PC? Or bias? Sorry.

So no improvement as far as you're concerned, Remy?

There will be 90 lb of cells on the LH side, plus steering box and MC.

I like the Christmas light idea though...

 

[jclars]

With my bias toward ICE, I will call this configuration my V18 solution.
Row of 9 each side. Leaves 6 more to fit in somewhere.

If Tesla Type S were 2" shorter, I could do 4 in front and 2-3 in rear at gas tank hole.

 

[remy_martian]

I'm enjoying having a second smartass on the forum...it got lonely at times 😂

 

[jclars]

I asked my daughter once how she had managed to get so many smart asses in her coffee shop.

Well, Dad...

 

[jclars]

Well, the Post Office helped sort this out. And maybe some comments about weight distribution from you guys...

I relooked at the Tesla Type S packs and had a PO flat rate box laying around that closely duplicated it dimensionally. So once I determined that I could get 4 centered in the front, and still be able to view the motor, I went to the PO and got more boxes. This arrangement still puts the batteries in a potential crash zone, so I may look at some additional protection up front. The bottom pack currently sits 2" off the motor (white bucket), so I am hoping to lower the lower battery to within 1" of the motor.

The rear packs can still fit in the old gas tank hole. Except now I will use 2 ea for a total of 110# which more closely resembles what weight I am displacing.
The four (4) front packs at 220# plus motor weight of 120# will also come close to the same ICE displaced equipment. Total resulting voltage is 136.8V.

 

[remy_martian]

What's on the firewall that's pushing the lower two boxes forward? I don't see anything in this pic:

Because the boxes say "priority", you need to get them against the firewall and pull everything else off, if possible...it looks maybe like some stuff got snuck onto the firewall after this photo was taken, or I'm missing something.

 

[jclars]

Good catch!. The PO boxes are actually 2" short of what the Tesla pack is. I pushed them forward to get the true feel at the front, rather than the back. I am contemplating staggering them up the slope of the firewall, but the top two are held back from the stock 12V battery box. However, I will probably get a narrow AGM batttery to gain that back.

 

[remy_martian]

I.C.

Since you're an ICE guy and all, what about an upside down "V"...can you get them 2 across that way, lower the c.g., and make @joekitch jealous with the "V8 look"?

Darned steering columns are always in the way...

 

[jclars]

You are correct. One of the reasons I abandoned the V18 idea was the steering column takes up the LH side. Well, that and good advise from the Post Office.

Maybe a flathead 12 look?

 

[remy_martian]

I'm not advocating it, but....

Wizard Fabrication I Steer Clear Offset Steering Coupler | 916-736-0110

 

[oudevolvo]

Lars (oudevolvo),

I went to your website where a Volvo 120 series is pictured: Enabling your electric car conversion project - EVcreate

It appears to have a front battery box tucked up to the firewall on the passenger side. Is this the combi project? I thought the combi/station wagon used primarily a rear battery box. Can you provide details and why only one on the passenger side?

Thanks,
John

Yes, that is an Amazon wagon.
The unit at the passenger side is the inverter.
In the center as close to the firewall as possible (deleted the heater) were 3 Tesla modules in a box. Five more in the rear.
That is needed for a proper weight distribution.
You can find my build blog here https://www.oudevolvo.nl/en/
At some point I stopped blogging and you can find updates here OudeVolvo and here https://www.instagram.com/oudevolvo/
Beware! No happy ending.
See Electric Volvo Amazon wagon from 1967 and converted to 100% electric for overall specs and rebuild process.

 

[jclars]

Thanks Lars - I already read the ending, which was certainly not happy!! I will look at your other build threads to see your layouts. I am prone to not totally delete the heater box, but I think it is more off to the side on my PV, over the steering column being discussed above. Hoping to get the canEV electric heater core to work.

Wondering why weight was more distributed rearward. The wagon was obviously meant to haul cargo, so perhaps that made the space more available?

John

 

[oudevolvo]

Yes, wagons have a lot of space in de back, but it’s all behind the rear axle.
Optimum for handling is a 50:50 distribution.
Some details here

https://www.oudevolvo.nl/en/blog/2017/06/08/weighing-wagons-battery-distribution-decision/

Nowadays I use racing weigh scales, but in 2017 the regular scales approach worked out fine.

 

[brian_]

Optimum for handling is a 50:50 distribution.

50:50 is not universally the most desirable weight distribution, but it's a reasonable place to be. Did you mean optimum for this specific model of Volvo? Many vehicles routinely carry more weight on the rear axle when fully loaded, even with identical tires front and rear.

 

[jclars]

I am simply trying to emulate the original weight I have removed. Per previous posts, my problem has been getting it lower to the original center of gravity. Weight distribution has not been at issue. I think I am getting closer though!

 

[jclars]

A thought occurred to me that the original ICE was weighted to the LH side. I mounted the exhaust manifold, intake with carb and the generator on the ICE as it sat on the floor:

The RH side had the somewhat lighter plastic heater blower with fresh air intake. It sits above the steering column and I have been trying to keep it in mind for reuse.

The offset to the passengers side gives me an opportunity to perhaps lower the CG, but I kiss all motor show casing goodbye.

You guys knew that I'd come around, didn't you...

 

[jclars]

This preliminary layout might be one result of shifting to the left. It puts one pack on its side to lower it by 3" overall.