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1995 Eagle Talon AWD : Kostov 11 : Soliton 1

45K views 122 replies 16 participants last post by  Old.DSMer  
#1 ·
I've been reading, researching, and planning for a long time. I picked up a '95 Eagle Talon AWD in April of 2012. Its not the 'best' candidate for an EV, but I like the style, the AWD, and the aerodynamics (0.29 Cd). The 2.0L turbo is very snappy once it spools up. I did some power comparisons in this thread and decided on the K11-250 motor. The Soliton 1 followed right behind it. Batteries are still up in the air, but the plan is 60Ah to 90Ah Sinopolies or CALB greys. Voltage will probably start around 160 for preliminary tests and then work up to 300V for the final design. It should yield about 160kW at about 6C (with the 90Ah). I could push the 60Ah harder, but I'll see how things evolve.

My blog is evtalon.blogspot.ca and I will be trying to keep that up-to-date as possible. I've been going through all the mechanical and have just started on the conversion. So far, I've pulled the engine, dropped the exhaust and separated the transmission.
 

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#3 ·
Thanks RW!

A bit over-due, but progress is slow as you well know :D

This is a great forum for discussing possibilities and solutions. Every one of us is custom building something, so its always nice to get some other opinions and input. As well as draw on the extensive experience in these forums!

So I'm all ears :)
 
#4 ·
Glad to see you here.

The 0.29 Cd is a really good thing... I know what I'm talking about considering my 0.38 Cd Smart fortwo (aka little Brick!)...:eek:
What kind of schedule do you expect? Date to first road test? Date of purchase of cells?
 
#5 · (Edited)
I had a 95 Tsi, bought new and drove the crap out of it.... fun when you keep the turbo spooled up, but pretty heavy around town. I always had problems with windshield fogging like crazy in the winter.

you're going to have to retain power steering probably.... so plan on an electric pump for that.

EV build wise..... an 11" motor will be a screamer, and w/ awd you might keep it on the road. ;) I would suggest NOT 'phasing' in more batteries for higher voltage later. You really don't want to deal with different ages of cells potentially from different batches, changing your charger, dc-dc, etc. Also, a word of caution in going over 160v nominal is that components get a lot harder to find and much more expensive. To keep weight and cost down, I'd stick w/ 156v nominal x 100ah 'new' CALBs unless you REALLY need more range. You're going to run out of room pretty quick since the drive train limits where you can hang battery boxes, unless you give up the micro rear seat/cargo area completely.....

oh, just checked your blog.... was wondering if you would have room for an 11". you might be better to switch to twin 9" ?! If are still considering an offset, ReBirth has done some pretty wild twin adaptors that are offset.
 
#7 ·
I had a 95 Tsi, bought new and drove the crap out of it.... fun when you keep the turbo spooled up, but pretty heavy around town. I always had problems with windshield fogging like crazy in the winter.
It is a fun little car :D

This was my first winter and I only had fogging issues once - it was extremely cold and there were other vehicles with window issues as well. I find keeping the AC running dries the air and reduces fogging as well. One of my older vehicles had a slow leak from the block heater - and it was a nightmare. But so far, so good with this one!


you're going to have to retain power steering probably.... so plan on an electric pump for that.
Yep, already have a PM motor from another project that should do the trick. I'm thinking about a PWM circuit to modulate pressure and maximize efficiency of the stock gear pump. I'm also keeping the AC - currently investigating electric options, but am also planning to run it off the secondary shaft.

Also, a word of caution in going over 160v nominal is that components get a lot harder to find and much more expensive. To keep weight and cost down, I'd stick w/ 156v nominal x 100ah 'new' CALBs
My motivation in going HV was to keep max current lower and thus reduce resistive losses and potential thermal issues. Perhaps phasing will be a bad idea, don't know? The spare tire well is cavernous and there is alot of room under the hood. I might even do a small pack in the existing fuel tank location (under the rear seat) - not sure about dimensions though, I have to remove the tank yet.

We discussed the dual 9's in my other thread - I still think that setup looks mean and would generate some interesting discussions at the coffee shop. But the added weight and cost wasn't a benefit. And a 9 would still interfere with my transfer case.
 
#8 ·
Latest Problem:

The K11 interferes with my transfer case (red line). So I'm going to have to come up with an offset drive setup. I really don't want to remove the AWD (thats why I picked this car, after all !!!). So time to get designing and see how a silent chain drive might work....

Its a common setup in almost all transfer cases in SUVs and 4x4 trucks. Correctly designed they can run quietly at 99% efficiency and 40m/s linear speed.

I'll have a very tight center to center on the shafts and the chain case will be extremely compact (2-3"). Anything wider and the motor will interfere with my front frame rails.

Below is only an example of an NP242 from a Jeep. I'll try a similar idea, just much more compact. 6061-T6 aluminum case/adapter plate combination. Time to get cracking on a design....
 

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#9 ·
Latest Problem:

The K11 interferes with my transfer case (red line). So I'm going to have to come up with an offset drive setup. I really don't want to remove the AWD (thats why I picked this car, after all !!!). So time to get designing and see how a silent chain drive might work....

Its a common setup in almost all transfer cases in SUVs and 4x4 trucks. Correctly designed they can run quietly at 99% efficiency and 40m/s linear speed.

I'll have a very tight center to center on the shafts and the chain case will be extremely compact (2-3"). Anything wider and the motor will interfere with my front frame rails.

Below is only an example of an NP242 from a Jeep. I'll try a similar idea, just much more compact. 6061-T6 aluminum case/adapter plate combination. Time to get cracking on a design....
What's inside that offending case? Any chance to just modify that case, perhaps just cut it along the green line and seal it against your motor?

It's hard to judge from the picture, but if the gears don't interfere and the cap has no structural duty it could be possible.


Regards
Ektus.
 
#11 · (Edited)
Ok dumb question: what kind of adapter are you planning? Pretty certain my CAN-EV adapter will clear the red / green line area if I whacked part of it off. Probably not even need to whack stuff off the adapter because it sits back about 2 inches . clutched or not, wouldn't matter, but the Ranger shifts so much faster and easier with the clutch
 
#15 ·
Hi piotrsko, the adapter itself could be trimmed to clear that area. Problem is that the K11 motor is the diameter of the green line. The transfer case is about 6" thick and interferes with the motor. I'd require an adapter at least 6" thick to move the motor away from the transmission and clear the transfer case. I cannot do that because the motor would then hit the front frame rail. So the only option is to offset it.
 
#12 ·
Old.DSMer
I have the exact same problem on my 4wd transaxle! Been limiting myself to motor diameters ~220mm/8.5" which really hits the power capability. Alternative is a longer motor, btu I am talking AC motors.

That Kostov is a great choice of motor in my opinion, have you already purchased it? What power/performance are you looking for? Would you consider an AC motor to avoid the offset drive? There are various options. I'm contemplating a few, but for power density, a dual EMRAX motor setup seems ideal, 225mm in diameter, and potentially 200kW (gross input to controller) max and nearly 100hp continuous with liquid cooled BLDC motors, 2300Euro each.

I found a few US companies offering suitable AC motors but dismissed them as I am in the UK and the cost to buy from US would be prohibitive.

What is the maximum diameter your transfer box will allow? it looks quite similar to mine. Mine is in a Toyota Rav4 by the way.
 
#16 ·
Old.DSMer
I have the exact same problem on my 4wd transaxle! Been limiting myself to motor diameters ~220mm/8.5" which really hits the power capability. Alternative is a longer motor, btu I am talking AC motors.

That Kostov is a great choice of motor in my opinion, have you already purchased it? What power/performance are you looking for?

What is the maximum diameter your transfer box will allow? it looks quite similar to mine. Mine is in a Toyota Rav4 by the way.
Hi tylerwatts, interesting your Rav4 is so similar. What year is it?

I investigated some AC options, but everything was out of my price range. The K11 and Soliton1 yielded the best bang for the buck so to speak. And I was graciously able to drive RW Audios car - he's using a Warp11. AWESOME. And he didn't even have his final battery pack complete! So, yes, I already have the Soliton and K11.

Ultimately if I can run 200-250hp, I would exceed the factory output and be very happy. Hopefully without breaking any drivetrain components!

My limit is also about 8.5" diameter. As stated above, I'm going to offset the motor to increase clearance and improve center of gravity slightly.

My week is swamped, but I'm trying to get something drafted up in the next week or two.
 
#17 ·
Hi. Mine is 02, the last series of true 4x4 models.

Can you post a top view photo of your trans in the nine bay pleas? Is your motor a twin haft? I wonder how much length you can save on the motor by removing the fan and shortening the end housing. For cooling I would then consider a turbo cooling kit from evtv that I would force the air into the motor from the coupling end and offset the coupling/mating to the trans to clear the motor and transfer box.

But this is all speculation without a photo of your engine bay. Unfortunately I am totally unfamiliar with your vehicle, this was the first time I'd heard of one. By good looking car though! And love the awd!
 
#18 ·
Oh I read it is sister to the Mitsubishi eclipse! Very nice cars those! Bullet proof mechanicals so should love the ev motor. Forget first gear though, waste of time with the Kostov11. I'm seriously thinking the best option is to strip a stock manual trans and keep 2 optimal gears for a low and high speed that should mean one doesn't need a clutch either.

I'll admit I've been thinking of it with AC motors in mind and using speed control when changing gear to match motor and gear speed to save the synchros. But it should be ok with a light Kostov DC motor.
 
#19 ·
Hey tylerwatts,

The 2002 is still one of the 1st gen. And wasn't it available as an EV? Or was that version only FWD?

I definitely wanted the AWD for winter months. And the added traction in the summer couldn't hurt. Especially if I make it out to the drag track :D Yep, its the sister of the 2g Eclipse.

Things are so busy, I don't foresee making it into the garage for another week. Modifying the case is something Yabert and I have discussed a little outside the forum.

I have some pics of the ICE removal in my blog. Also attached a couple I found online. The outside tips of the starter ring gear are about 10.75". And it runs behind the transfer case - just over 1". I'll have to do more detailed measuring of the motor to see if there is enough room for mods.

Which brings up a new question -- has anyone with a clutch ever had issues with the cooling fan sucking in clutch dust and contaminating the motor bearings?

The gear ratios are very tight. I doubt I will use 1st or 2nd and I might remove those gears at a later date.
 

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#21 ·
Which brings up a new question -- has anyone with a clutch ever had issues with the cooling fan sucking in clutch dust and contaminating the motor bearings?
Why suck? The Kostov motors don't push the air from Commutator End to Drive End?
I think the answer is yes, like the Warp motors done.

It's nice to see more picture of your problematic. Custom and strange shaped adapter will be needed.
If I consider longer adapter and shorter motor (K11 modified or K11 Alpha is 1.5'' shorter!!) I hope there are enough place to mount motor in straight line with your transmission.
 
#20 ·
Old.DSMer
Mine is first of the early second gen models. 2002-2005, bofre the facelift when the drivetrain was made 'on-demand awd' with a viscous coupling (I think) meaning it was predominantly fwd most of the time.

Removing the gears sounds a good plan. And if 3-4-5 are close you could lose another and then only shift front-back like a high-low shifter. Might not need the clutch then.

Your bearings should be sealed so no problems with clutch dust, I'm sure the Kostov's are sealed! Clutch dust is not much different to brush dust, so at service intervals just clean out the dust with a small wire brush and air gun. Not heard of any problems with bearings from it.
 
#23 · (Edited)
Old.DSMer
Mine is first of the early second gen models. 2002-2005, bofre the facelift when the drivetrain was made 'on-demand awd' with a viscous coupling (I think) meaning it was predominantly fwd most of the time.
I see, so its the 'traditional' 4x4 where you should only use it on slippery surfaces. But then you know you are actually IN 4X4 when you want it! My Jeep used to have an extra differential inside the transfer case for 'full-time' 4wd. But that meant you could only have 1 wheel transferring power. It still worked very well and was much better than just RWD. The Talon has a viscous coupling. Given its age, it still seems to be performing great. I hope it holds up to the large torque from the electric motor.

Removing the gears sounds a good plan. And if 3-4-5 are close you could lose another and then only shift front-back like a high-low shifter. Might not need the clutch then.
Exactly. It would save weight and reduce rotating inertia and oil drag.

Do you have a build thread?
 
#24 ·
No mine is full time 4wd. No transfer case. it is almost the same layout as yours but with central open differential rather than viscous coupling.

No build thread as I have no build as yet. Got loads of info off the web adn forum and still strategising which direction to go. No options are popping up al the time and there is litle documentation inteh west of Eastern Eurpoe's products and there seems to be abooming industry with great produts that I am trying to fin about, and also chinese (how dare I, I know) products are available and at good quality.
 
#26 ·
Transfer Case Update

I've been spending alot of time scouring the web for existing parts I could modify. I also investigated a custom chain-sprocket design.

Turns out the most cost effective will be to utilize existing transfer case parts. The bearings, seals and couplings are readily available - just a matter of determining what will go where.

I still have to source an external electric oil pump because the chain requires pressurized lubrication.

I'm waiting on final costing of the aluminum case and 4140HTSR shaft - but have most of the internals worked out already. 4140HTSR is overkill, but I have access to some crops. The images don't show the flywheel or clutch, but they will be retained. The output shaft end copies the factory crank.

Sadly, I could not get enough room by eliminating the fan and shortening the rotor. And I didn't really want to hack up my nice new motor anyway :)

I still have to finish the motor mount for the auxiliary side. It will also incorporate an idler bearing for the front drive shaft (which was previously bolted to the engine block). Fun times....
 

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#28 ·
Driving sprocket will be directly attached to the K11. I can't find a bearing part number on that motor, but it looks beefy. And the shaft is very short, so it will have a small bending load.

Output sprocket will be attached to a double-supported shaft. I think I might replace the spherical with a tapered bearing and lock nut - just like a wheel hub. That will enable me to preload the drive end and keep things rigid.

The flywheel/clutch will mount up just like the original (not modeled up yet).
 

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#29 · (Edited)
Nice drawing Old.DSMer...:)
But sad solution! So much complex. And all this will reduce efficiency and reliability while increasing the weight...:(

Maybe can you send me the transmission and motor CAD (step, igs or ?) and I can try to find simpler solution on my side. I'm specially interested by your problem.

If no, I suggested you to build a double-supported hollow shaft on the motor side. Rigidity will be increase and the sealing will be easy. It's how than most manufacturer build their single speed gearbox.
You need to know than motor shaft is floating (can move on his axis (I guess 0.015'' to 0.060'')) to allow his expention under heating. Maybe that can cause your drive sprocket to move a bit (a problem?).
 
#30 ·
Modifying the K11 Motor

Maybe a Solution?


Thanks for your persistence in talking me out of the transfer case concept Yan and tylerwatts!!!! :D

In the spirit of the almighty KISS principle, I tore apart the K11 motor.

I can gain at least 2.5" by removing the fan and modifying the aluminum end cap. By the looks of that fan, an external unit with a shroud and some ducting would probably work much better anyway. If I trim a bit of the steel motor housing, I might even be able to gain 3".

So that all means I should be able to use a 3" spacer plate with a direct coupling to the flywheel/clutch. Yay!!! :D

So anyone have suggestions on removing that bearing? My splitter does not fit between the fan and race. And I don't want to use my gear puller because it only pulls on the outer race. So....what next?????
 

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#31 ·
Re: Modifying the K11 Motor

I just used a gear puller. I too don't have my fan connected because it is too long to fit in the VW with the fan connected. I too plan on a shroud with blower hole and also feel it will be better. Mostly because I have that for my GE motor and you really don't need the internal fan. The other benefit is that removing the fan gives you access to the end shaft for other things. Like RPM sensors.

I had it in my VW Bug for awhile and now its going in my VW Roadster. Installed yesterday. Still need to build a shroud. For short runs it works great without the fan. Lots of open area for heat to just dissipate. For long runs I will need a fan.

I like my Kostov 11"

Pete :)

Mine is the older model that has a different sized shaft and bolt pattern. I put in a new brush ring and bearings and brushes.

Heat the bearing before pulling.
 
#33 ·
Yea thats the problem but if you more warm the bearing and direct maybe a tight flame to the inner race that slips on the shaft you may have no issues. Just flaming the whole bearing would not be so hot. I am more advocating to warming and not like red hot heating. Just warmer than the shaft. Might help slip it off.
 
#36 ·
I am more advocating to warming and not like red hot heating. Just warmer than the shaft. Might help slip it off.
I might have to try this - but its going to be very difficult (almost impossible) to heat JUST the race. I'll have to think about it a little more.

I a previous job, we did heat races - but they were all 2pc bearings. I've never done it with a sealed 1pc.
 
#35 ·
Hey Old.DSMer, are you in Alberta? I see you had a chance to drive RWAudio's Porsche in the Calgary area. I'm up in Edmonton, I'm helping with an EV and alternative fuel vehicle show and conference here April 27th. Sounds like RWAudio is bringing his car, should be a fun time! I put up a post about it under chit chat, check it out on this link.

Glad to hear you're going with shortening the motor over trying an offset drive! As for the transmission, I stripped out the transmission gears on the mini truck as direct drive through the transfer case to the diff gave a good ratio and I figured I wouldn't need any lower gearing which is all the trans would have provided anyways. I kept the empty transmission case as a convenient way to mount the motor to the integrated transfer case. It does work well in direct drive 95% of the time but there are situations where having a gear or two lower would be nice and it was a lot of work and hassle to disassemble the transmission and get it back together with missing gears! If I were doing it again I would just leave it as is. I don't know what the drag penalty would have been but in your case I doubt removing only one or two gears would make a noticeable difference. Unless someone has some data to prove me wrong? I like data!

Switching to lighter weight synthetic fluids will have a large impact for you though with two diffs and the transfer case along with the transmission. I noticed a big difference on cold mornings when I switched my trans and transfer case from 75W90 to this synthetic ATF,
http://www.redlineoil.com/product.aspx?pid=51&pcid=9.

I did a powertrain drag test with the wheels in the air before I switched and will do another before and after I switch the diff fluids to synthetic as well. It took 3.5kw to spin the tires 60km/hr in 4wd with the original fluids, it only took ~8kw to drive the truck that fast!

Good luck!
 
#39 ·
Hey Old.DSMer, are you in Alberta? I see you had a chance to drive RWAudio's Porsche in the Calgary area. I'm up in Edmonton, I'm helping with an EV and alternative fuel vehicle show and conference here April 27th.
Yep, Edmonton as well. I was going to look you up and get more info on that show. I'll definitely be there to view/chat! But no vehicle entry for me....

...stripped out the transmission gears on the mini truck as direct drive through the transfer case to the diff gave a good ratio and I figured I wouldn't need any lower gearing which is all the trans would have provided anyways. I kept the empty transmission case as a convenient way to mount the motor to the integrated transfer case. It does work well in direct drive 95% of the time but there are situations where having a gear or two lower would be nice and it was a lot of work and hassle to disassemble the transmission and get it back together with missing gears! If I were doing it again I would just leave it as is. I don't know what the drag penalty would have been but in your case I doubt removing only one or two gears would make a noticeable difference. Unless someone has some data to prove me wrong? I like data!
I'm planning on keeping the tranny stock for now. If I do end up removing any gears, I'll probably do a full rebuild and upgrade the internals to Stage 2 or 3 class so they can handle more torque. But I need to focus on getting it on the road first :rolleyes:

Switching to lighter weight synthetic fluids will have a large impact for you though with two diffs and the transfer case along with the transmission.
Definitely agree - I switched everything to Redline as soon as I got the car.

I did a powertrain drag test with the wheels in the air before I switched and will do another before and after I switch the diff fluids to synthetic as well. It took 3.5kw to spin the tires 60km/hr in 4wd with the original fluids, it only took ~8kw to drive the truck that fast!
I plan on doing some wheels-in-the-air drag tests as well. I might even pull off the brakes to see how much extra drag they add compared to spinning just the drivetrain by itself.