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Well my EV is almost done (link to pic below) Test drove it this weekend. Tranny is a problem and some other things to do. I have gotten much help from a couple of engineers without whom I would have a junk pile.

Now I am thinking about safety. What do you have as your safety items (baking soda, rubber gloves etc)? Because I'm new to this, I figure my chance for error is high so I want to be safer than most.

In addition to the items themselves, a list of best practices (wear rubber soled shoes?) would be appreciated. I would think this could be a sticky post or document.

I would especially appreciate links to specific items such as the gloves. Surfing the web I read that someone recommended gloves UL rated for 600v. I can't find a description like that online.

https://picasaweb.google.com/lh/photo/wTqnacPVy7ExXoOkD3BIMg?feat=directlink

Thanks.
 

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Very nice! What's wrong with the transmission, synchros? I have a VW Cabrio (2 actually) that will go through similar treatment so I'm glad you've documented yours like that. Do you have a build thread?

Taking hints by EVTV, they've used heavy duty heat-shrink on their tools to help with safety. There's always the good practice of not connecting the negative side of your battery pack to the car's chassis or 12V neg. I would also do as much one-handed work as you can when working near the pack. Keeping the pole connections away from all other things and covering your pack connections with an isolating material is also good.

JR
 

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Hi.

I think the problem w the transmission is in the linkage. It doesn't shift and there seems to be little resistance. Any ideas"
So your shifter is sloppy and moves all over the place? That surely sounds like the shift links are done.

I just went through the same thing literally 2 weeks ago with one of my Cabrios. There are two options to get this fixed: a linkage rebuild kit with the original plastic bushings, etc or a heim joint based kit from USRT ($145). I opted for the latter and I'm glad I did. All slop is gone - for good - and it gives it a real nice and solid feel to the shifter.

The USRT is not easy to install, especially if you just follow their instructions. Funny but true. See this link for a actual installation: http://forums.vwvortex.com/showthread.php?2312069. If you decide on it, I recommend these guys to buy it from: http://www.germanautoparts.com/Volkswagen/Cabriolet/Transmission/186/1

JR
 
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