292: Saturday 24th June 2017

 
It's been a while since the brushes burnt out on my old DC motor and I started the change to AC. I had painted the new bracket for the rear motor mount and went out to fit all the brackets. I had forgotten to paint the modified driveshaft bearing support bracket. So I painted that and then spent some time tidying my tools away. I have been working on my kitchen at the weekends and spent one weekend in Dublin Ireland to see Kraftwerk live at the gas board theatre. Today I got back on the Probatron conversion. I needed to strike a compromise because I still have things to do with the house and the car, so I am doing car on Saturdays and House on Sundays until both are moved on. The picture below shows the new Curtis controller and my old DC-DC converter positioned on my old heat sink that I had for the Zapi controller.
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Had to do a bit of drilling and cutting the fins on the heat sink to get the bolt holes lined up on the controller. I also mounted the throttle brackets and fitted a new spring to the throttle box. I then mounted the whole assembly onto the car brackets. The controller was touching the brake pipes on the firewall, so I gave the pipes a tweak with a hammer and a block of wood then it bolted in just fine.

291: Sunday 7th May 2017

The last 2 weekends have been about changing from DC motor and controller to AC. I had the brushes burn out again around Easter time and I figure now is the time to change to AC (no brushes, better regen capabilities). The picture below shows the controller and charger removed with the old motor still in the car. Notice there is only a small gap between the motor and the body.
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I found a company in UK that had some HPEVS AC-50 motors and was able to get me a Curtis 1239 controller for a reasonable price. This works well with my existing 120v battery pack. This is a smaller motor than what I took out and also the controller is a lower rating, but the cost to get performance is too high. I found the low speed performance of the DC motor to  be excessive for my journeys, but the AC system behaviour is so much more configurable with the Curtis controller.
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The motor fixings were the same as the old motor including the 4 threaded bolt holes around the perimeter and the shaft size was the same. The only difference was the shaft was shorter. The old motor had an 11mm spacer to hold the taper lock hub off the motor. This provided the right geometry for the clutch to be in the correct position for the actuator. With no spacer, the hub was rubbing on the motor. With the 11mm spacer, the hub was hanging off the end of the motor shaft. Neither of these conditions was acceptable. My neighbour Luke has a friend who has a lathe in his garden workshop so we went to see him and he made the outer mounting ring 9mm shorter and made me a 2mm spacer This then gave the same distance as an 11mm spacer. You can see in the photo below the hub is lined up nicely with the end of the motor shaft. I had to cut the stepped key to match this length. I inserted the adapter bolts around the edge of the hub before locking the on the motor shaft. I then added the flywheel adapter, then the outer ring and bell housing adapter plate, then the flywheel and clutch in that order. I mounted The motor last Saturday with help from my friend Sandy
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The place where I got the motor from had some other bits that I paid a bit extra for such as wiring looms, shaft key, motor bolts, rear motor cover and this rear mounting bracket. At this stage as shown in the photo I was on my second attempt at marrying my old mount and this new one. I had cut off the bent part of the bracket as my first attempt was to add an extra 12mm of metal to bridge the gap difference with the old mount. I Decided to just use bigger angle section and replace the whole end of the new bracket. I had to cut another slot for the transducer cables on the back of the motor. The bracket is just tack welded in this here.
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Monday night I went with my neighbour Luke to his workshop where he MIG welded the joints, then went over them with a TIG welder to make them look neater as this will be on show. We added 2 triangles on the back and one on the front to provide extra strength and rigidity and help prevent any twisting. These were also MIG and TIG welded. I just need to give them a good coat of paint then it is ready to go back on. We also re-made the drive shaft bearing support bracket to fit this new motor set-up.

290: Sunday 23rd April 2017

On my way home from work just before Easter and sparkie broke down with the motor arcing. Got the motor out today and 2 of the 8 brushes have gone and the rest are badly worn. I am going to take the plunge and change to AC. I'm going with a HPEVS AC-50 motor and a Curtis 1239-8501 at 120v. Also the taper lock was broken on the flywheel hub, so that explains the clonking when pulling away.

289: Tuesday 4th April 2017

Saturday my friend Sandy came round and helped me get the air receiver fitted for the air suspension system. The feet on the receiver almost exactly matched the rails they were going on to. I pulled out some 40mm L section mild steel and we made 2 brackets to fix to the rails. We then drilled holes in the sides of the brackets to bolt the receiver on and then offered it up to the rails to mark through the other holes. We then drilled the rails and fitted the tank to the car. Last job for Saturday was to paint the new brackets with smooth red Hammerite.
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Sunday Morning I bolted the receiver tank. In the the photo below you can see it in the car nice and secure. Next job is to make a bracket to mount the compressor pump and valve block.

288: Friday 31st March 2017

Last Saturday I set out to make space for the Air suspension equipment. The main space is needed for the Air Tank that is about 550mm x 260mm diameter. Also need to mount the compressor and the air management valve block. I took out the old battery racks that were left over from when I had lead-acid batteries in the front of the car. I had to put his back so it was supporting the front slam panel for the hood. This is not a very strong panel and I had to cut the original mount to get batteries in there. So with a basic frame prepared I moved the Anderson Connector, Current shunt and wooden mount, brake vacuum pump and the gauge driver circuit as well as re-routing the cables. The Air Tank drops in right on the frame (by luck) so I just need to make some brackets to fix it down.

287:Monday 20th March 2017

Been busy this last few weekends. I got a new head unit. I had to remove the display from the places for the centre console air vents and perform some serious surgery. I cut out the front panel so there was space to see the whole of the 7 inch touch screen. and get to the volume knob. I used a soldering iron and a file to fold the edge of the plastic over where I had cut through. It was a tricky operation that I wouldn't want to repeat. I had to cut out the vent duct from behind the unit too. I used the cradle from my old head unit and with some cutting and bending I fashion a bracket for the new unit to sit in. I had a couple of looms already I used to make a new loom for connecting to the probe. The problem is that the euro connector wants to connect speaker outputs to line inputs on the Probe pre-amplifier. The head unit had RCA Phone output on it so I soldered RCA phone connectors to the loom and connected straight onto the head unit. The previous head unit only had 2 phono outputs so I had to join front and rear together. this one had 4, so no problem. Sounds so much better. I need to replace the rear speakers, but I have some from a Ford Cougar that fit correctly and shouldn't fall apart like the last ones.

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With the new head unit in I have been driving round for the last 2 weeks with no battery monitoring displays. This made me a bit nervous, but I just gave myself an extra safety margin on the distance and stuck to it. Yesterday I finished mounting the displays and it's all back together now. I just need some clips to hold the front panel in as they are missing and it springs out slightly, but will push in very easily with the clips. I used layers of hardboard to make a mount that the displays fit into.
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The layers were glued together and place under a car battery while we went to watch my daughter play football and win 5-0...!
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Then the felt was stuck on to make it look OK for fitting in the front panel.
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The displays were secured using screws with washers around the edges on the small touch screen and some specially made clamps for the JLD 404 unit.
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The whole face panel was then fitted back in the centre console. I needed to do some shaving inside to get the JLD 404 in so it was not being pushed sideways. I also had to mount the stop button and the 'forward / reverse' switch on the top of the dash. The gear shift was in the way of the JLD 404 when I was in 3rd gear (normal) so I have to look round it. I cannot think of another way to get all this in. Driving in 2nd gear just feels weird. I might have to find a way of shortening the gear lever. It's another job to add to the list.
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Finally I have got my air-ride kit and that is the next job. I have opted for the more expensive kit with the ride management so I can preset heights and operate the suspension from my phone from outside the car. I tried to install the android app onto my head unit, but the manufacturer reckons I have the wrong version of blue tooth. I shall try a side loader, see if I can get it in and maybe it will work. Worst case it won't work and I'll just use the controller that came with it. The control panel looks like an iPhone...

286: Monday 29th August 2016

It's been nearly a whole year since I last posted. I haven't had much to say as everything has just been working o.k. I cannot stress enough about how much better the the Lithium Iron Phosphate batteries are than Lead acid. Yes they cost a lot of money, but now it is easy to buy a second hand electric car and get the battery from it as well as the drive motor, controller, all the connectors etc. I want to try and transplant a Nissan leaf into a Jeep Wrangler TJ. I want to keep as much of the Nissan as possible including the instruments. Nice project and used Nissan Leafs are quite cheap now relatively. This is much cheaper than buying all the parts. I paid about the same price for my latest batteries as I could get a whole car for now.
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I have added a tow hook that was originally from a VW transporter. Chose this one as it has a particularly long hook so the bracket is well behind the body kit. My friend cut the cross member so I could get the hook and the thread for it to go into. I ended only keeping the thread itself and making the rest of the bracket from 6x40mm angle section.
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I took a grinder to the front cross member to get some bare metal and welded the new bracket to it. Now if I get a problem I can get a simple recovery. The last few times I had to get a low-loader truck out to get me home. All those were due to problems with Lead acid batteries.
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I went to pick my Daughter up last night and I had to do a U turn at the bottom of the road and the fuses blew on the power steering. I had to drive home without it and the steering was very heavy as I have quite wide tyres. I had a circuit breaker to replace the fuses, but never got round to fitting it, so today I rewired the power steering and put the new circuit breaker in. All is working again now. 
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Now the towing hook is done and I have the USA type headlight covers, I am ready to revisit the bodywork to get ready for paint. Before that happens, air suspension is going on so I can avoid speed humps and kerbs, and slam it down when I park for a bit of extra coolness. Plans for the instruments include a new battery monitoring system that works via Bluetooth and an Android app, so I want to mount an android head unit. and also move the JLD 404 instrumentation and hence the forward/reverse switch and stop button.

285: Monday 31st August 2015

After getting the motor back on I was wanting some more instruments. I ordered this circuit from ZEVA in Australia some time ago that is specifically for driving normal car gauges. I used an existing bolt hole to mount the circuit.
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It took me about an hour to find the best spot taking into account that it needed to be away from any splashes, need to be able to access the trimmers to adjust the settings and be able to pass the main power cable through the sensor. I also needed to provide a 12v supply to the circuit and feeds for the gauges.
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The circuit is the plus version that drives the car fuel gauge, but this plus version also drives the rev counter showing Amps x 100, so my rev counter was reading 0 to 800 amps. So far I've only hit 700 Amps for a fraction of a second.
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The photos show the circuit, the mounting position and it's location in the car respectively. It is behind the main connector and one of the headlamps. The area was dry and it has been raining hard recently, so it is all good. I shall make a cover for it as well. The rev counter works really well and reads a little bit lower than the JLD 404, but the fuel gauge doesn't work in a linear way. That may be because the original fuel gauge sender was perhaps logarithmic instead of linear so what I get is the gauge, when full, drops very quickly at first and slows down as more capacity is used. It will take some getting used to, but I Like the idea of a simple gauge to check capacity so I can monitor overall voltage on the JLD 404 and eventually on the battery monitor circuit. That's one of my next jobs, to connect the battery monitor circuit back up so I can view groups of 4 batteries, then add some more analogue measurement boards to give me all 38 batteries. At least now all the batteries are together in the trunk, so wiring them all in will be easier. Then a posh cover for the batteries to top off the trunk.

284: Friday 28th August 2015

Much better this week. I got the Jeep on the road so I had some wheels. I got a replacement battery for free as it was still quite new. That meant I could give my wife her Focus back. Still need to fix the axle on the Jeep though. On the Probatron I had my motor commutator skimmed and it was still noisy, so I had new bearings fitted and a shim to push the armature away from the brush boxes. Spent this afternoon getting the motor back on and the arcing noise has gone and the motor is performing like new. It is an absolute joy to drive again. I feel so relieved to have him back on the road. The charger with its mods was working fine and I can finally put my first charge into the Lithium battery pack. Now I can determine the range with some test drives. The JLD 404 will be my gauge as I haven't fitted the gauge driver circuit yet. I have ordered a rear license plate as the current one looks terrible where the screws have rusted and it has stained the plate.

283: Sunday 24th August 2015

The last 2 weeks have been up and down. First I got to run with Lithium batteries. The batteries I had before were weak and I had damaged 2 recently leaving me stuck at the roadside, so I had to be careful with my driving and not load the batteries too much. During the last few months I have been getting motor noises. I have had clicking from the brushes, howling from the bearings and crackling from arcing. All of these are bad noises. After dressing the commutator with a comm stick and fitting new brushes the clicking got quieter, but the arcing was still there.
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I took the motor off again and had a local company lined up to repair it. They estimated one price, but then came back with a figure over £1000 and that was almost as much as a new motor. I asked for it back and was asked to pay £250 for testing and told this was to cover re-assembly etc. I got back the motor in bits with a broken taperlock hub and bush, and 1 brush and some brush springs missing. I eventually got all the bits back. I didn't pay any money to them. I then went to a long established motor rewinders who had the commutator skimmed for a reasonable price and advised that it may not cure the arcing, but to try it to see what needs doing next. I re-assembled the motor and the clicking is almost non-existent due to the professional skimming, but the brush box was arcing onto the side of the armature. This appeared to be due to the bearings as the armature was shifted over. I shall be looking to get a spacer fitted with new bearing to ensure there is always a good gap between the brush boxes and the armature.
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I could see when I pushed the armature, there was no arcing. I am not sure if this will cure the arcing under full load, but I suspect it is a good candidate for the cause. When the bearings were re-assembled onto the commutator a circlip was missed off and when I re-assembled the motor there was no bearing noise. When I was seeing the arcing I thought it was due to the bearing moving because there was no circlip, so I pulled the bearing off again, fitted it into the end plate with the circlip and fitted this back onto the armature. The armature was then close to the brush boxes, I struck the end of the shaft to push further into the bearing and the gap was then good. When I ran the motor, the howling had returned and when I turned it by hand it was possible to feel a rumbling in the bearings. I suspect this is where the howling is coming from, so I shall now get new bearings fitted and a spacer on the rear bearing to resist any lateral shift of the armature towards the brush boxes. This is a problem if I used the clutch pedal as it pushes against the flywheel and hence the motor shaft. The spacer only needs to be about 2mm, so a nice thick washer will do just fine.
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At the same time I have been trying to fix my wife's Jeep Grand Cherokee that has a noisy front axle. I took the axle off and inspected the differential. I saw a load of slack in the pinion gears, but no damage. In doing this I found the right wheel bearing had a horrible grumbling feel to it. I ordered a new hub and a socket for the hub nut, changed it over and spent half of today putting the axle back on the car. I took it for a drive and the noise is still there. Also the battery was dead so I had to get a jump and this did not take a charge. So now I need to use my wife's Ford Focus to get to work. I came into this weekend hoping to get 2 cars back on the road, and came out of it with none. So I fitted the new lights I got to the back of the Probatron and I am happy that something has gone to plan.
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I am looking forward to getting the motor working right so I can continue with my upgrades and get the body ready for paint again. I am getting close now to where I want the Probatron to be. Oh and a new license plate.