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There seems to be a lot of room under the floor at the mid rear of the car. Not sure what exactly your plans are, but I'm already seeing how the floor could be cut out and a battery box dropped in there.

Might want to spray some undercoating on those rust spots before wrapping everything up.
 

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No problem at all. Some use 144 volt systems with that (very nice:cool:) motor. Also remember that the harder you push the car, the more voltage drop you will see. There's nothing wrong with anticipating that drop by using slightly higher system voltage and its common practice to do exactly that.
 

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The only reason they priced it high is because they don't want to do it. If they did they would make a killing on it at that price. Lots of times, welders or other trades bid to cover there butts.
Well I am a wielder and I'm afraid you are correct. There are some projects that we will overprice because its not a standard item of us. Most of what we do is railings, so if some one wants a complete staircase out of aluminum we will price it farily high because it would cut into our normal bread and butter and we are not well tooled for that. Machine shops around here act on the same principle, but can take it to an extreme.

We don't mind doing small odd jobs and battery trays are not a big deal for ANY metal shop to make unless there is lots of sheet metal involved but even then its not that big a deal. Large out of the ordinary jobs I like to avoid when ever possible though, in the case of that staircase, he was expecting something comparable in cost to wood construction, which was not going to happen.

There are the exceptions to the rule though, and I was able to find a backyard machinist when I needed some custom machining done on an engine rebuild earlier this year.

Look for smaller shops that do lots of local work and are not snobs when it comes to dealing with smaller local customers. The problem is often they will charge an hourly rate, so if its the first time they make something like that up, they will take longer and might even drag their feet on purpose. Worst part is you have no idea what the price will be in the end. Ask for a writen price quote before letting them do the work and do not give a deposite. If the shop is worth its salt, those terms will not be a problem for them.
 

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I was a welder for 13 yrs, now a design drafter.. Glad to hear there are other trades guys around here. :)
That sounds like what I do. CAD drawing for each job, build it then install it. Mig and Tig wielding often on the same job. Only been at it for 6 years though. Pays the bills, and gives access to some pretty cool material and equipment suppliers.
 

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A jigsaw will work but take your time and don't force the blade or it could jamb on you (not fun with a jig saw LOL). Might also try using a cutting fluid if the blade tends to snag or get hot. It will make a mess, but there might not be much choice.

Plasma cutter would be luxury, and a standing bandsaw is the next best thing. If you have strait cuts to do (to get the rough size) a circular saw will also work if you get a blade with carbide teath. Just secure it very well to a work table, advance slowly and use full face protection, because those aluminum pieces are really hot when they fly off a high speed saw blade.
 

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I don't see a problem with that. Lots of guys just use a drill press and some careful measurements to make the adapter plate. Probably all I will do if I can ever find a good donor.
 

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update... I was looking through my conversion pictures and noticed that I took a picture of the measurement of the driveshaft.. Anyway, if the picture is to be believed (meaning if I had it actually lined up properly and not just sitting there for the camera) then I DID make a mistake when I wrote down the measurement and it is fine! So, oddly, here's to hoping I fu*#$d up!
But you're still going to double check it, right?
 

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It will be a few hours before I can wipe this grin off my face:D

Looking good.
 

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I don't see why you couldn't just raise it slightly if you find its too low.
 

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I've got mig and tig wielding machines in our shop and can do steel and aluminum. Too bad you're so far away....

Are you hiring a shop or just having trouble wielding yourself?
 

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Ahh, OK. The way you worded your post I understood you had a wielder of your own and simply was not able to make it work good enough. Yeah having some one come to your place to wield would NOT be cheap unless he's a friend that would work for beer or something.
 

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LOL! yes, holidays can be a real drag LMAO!!
 

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Now thats a way to celebrate the holidays in style:cool:
 

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Gongrats, Patrick. You have done a textbook conversion that any of us would be proud of.
 

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I understand the green leaf on the road, that seems to be from a ford escape hybrid, but I don't understand where they "EV" came from. What ford did that come from?

Looks proper though. And as it so happens, we are digging out of snow right now too....8" in about 8 hours and it still falling.
 

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I would have liked to see pictures too. I'm not picky though, pixs of the finished belly already installed will do.:D
 

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Last week I was at the Toyota dealer to have our Prius serviced, and I mentioned to the service guy that we had an EV now and he was asking about it so I stopped by there the other day to show it to him.. Pulled my EV into the service department and ended up having just about EVERY mechanic (and several salespeople) in the place surrounding it for about twenty minutes asking questions... they were VERY interested in the conversion and the fact that someone did one in their garage. Remember this is from the Prius service guys!

One guy asked me what made me want one and I told him our Prius was the main reason.. the more I drove the Prius around, the more I tried to make it run on just the electric motor (which of course they can only do for brief periods). So then I started looking into buying an electric car and found out the only ones I could afford (Tesla aside) could go 25mph. Who the hell wants that outside of a retirement community? So I started researching homemade and viola! A few months later and I have my own electric car...

funny thing is.. they all agreed. If I can do it in a garage for under 10k... why can't the big car companies do it en masse? Well, we all know they can. But when WILL they (again)? It was great having so many people interested and asking questions! Glad I did the website to direct them to for more in depth info.
Wow, that must be an awesome feeling. And this is your FIRST EV!!??:D Its almost too bad some one didn't take some pictures during your informal show in. Still quite something for even the sales reps being interested though.
 

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Yup, I agree with others. Second one that has larger letters is better.
 

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Thats good to hear. Glad you have it running again. The stance looks good too. Might be a little high in the rear, but if you put more than just two people in and add some luggage, it will be perfect. Better too much than too little right?;)
 
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