Sunday, December 18, 2016

Fabrication - Patch panels: Part XII and Powertrain mock-up

After a short hiatus in updating this blog, here comes an amalgam of few weekends.

Lets start by fitting the oil pan from the Volvo B6304F engine to the newly modified ZF GS6-37DZ transmission.

Oil pan fitted to the transmission and hoisted up in the air. I also attached the shifter assembly temporarily to the box with zip-ties.
During this time, I took "accurate" measurements of the assembly, so I can see how much to cut of the firewall and also to share the information to someone who might need it and reads my ramblings.

The full length of the package is 1375mm from the front of the oil pan to the middle of the shifter.
Oil pan length is 615mm and the transmission is 760mm from the bell housing to the middle of the shifter.

Wednesday, November 9, 2016

Fabrication - Patch panels: Part XI

Not much was accomplished during the weekend, but something and that is always better than nothing.

Without further adieu, lets get the pictures rolling...

First of all, I noticed when I was grinding the welds flat, that there were few pinholes in the welds... I marked those and contemplated if I should weld them up.

I will just lead the patches and be done with it. That will cover the pinholes and at the same time will smooth the locations nicely... if I do it correctly!

Sunday, October 30, 2016

Fabrication - Patch panels: Part X

This time a quick and dirty update as was the visit to the car.

Around 6 hours was spent with these "achievements", but one can only wonder why and how it took so much time...

First part of the left rear valance/corner patch. A bit difficult to weld it on as the original metal is heavily pitted/rusted, but still reasonably sound.

Monday, October 24, 2016

Fabrication - Patch panels: Part IX

Well it's Monday now so once again my timetables did not hold.

Well nevertheless, here is the update.

First job was to mark the inner quarter panels to be cut.
I decided that I would like to make a similar shape as the original corners, so I measured 5cm upwards from the cut line.

Sunday, October 16, 2016

Fabrication - Patch panels: Part VIII

This time around post gathers happenings from three different weekends, so it's a "bit" long one and picture rich.

Lets start by welding some metal back... and taking some more out.

I manned up and welded this piece in that I have made few months ago.
The reason for this delay was that I was hesitant about those dimples I made. Then I figured that I can always take it out or refine it more when I have the proper tools to make proper "speed holes".

Monday, September 5, 2016

Fabrication - "Racing Battery": Plans - "Q & A"

I have received few comments about these battery plans and therefore I'm transferring them also to here.

B: "Although many of the products commercially available do not incorporate a proper BMS (battery management system), I would highly recommend including that in the mix especially if the cells are second hand.
The cells are not identical even from the factory and different operation conditions will have induced further deviation in performance and most importantly internal resistance and capacity. Over time these differences tend to create voltage differences between series cells and for this reason, the battery should be periodically balanced. The most popular way is to use dissipative balancing at the end of a charge cycle."

A: I have been thinking about integrating a BMS to the pack, but there is some contradictory information about them.
On the other hand, it would obviously be better for the cells and would be nice to know what the cells are doing, but it would add another point of failure to the pack and it would limit the usability of the pack by cutting the use too early.

Also there is EV packs, that have been running for multiple years without a BMS and the cells are "balanced" naturally.
You can check it here and here That is of course only one man's experiences, but nevertheless.

I'm also going to check all the cells by charging them and then discharging them and again charging them full and leaving them to storage so I will see if they lose their voltage.

I will be using this kind of charger for this:
This way I can see if they are OK as if they are not, they will warm up when charged and that cell will be disposed off. Charging current will be safe at ~0,3A and therefore no problems should arise.
Again Jehus' views in this matter:
Thankfully he's collaborating with EV West so maybe he knows what he is talking about...

By discharging them I will see how high the Amperage of the individual cell is and I can group them together so the series packs are as similar as they could be.

B: "To cancel out individual cell differences and to drastically reduce the channel count of the BMS, I would suggest a 30s4p 30p4s configuration instead."

This possibility you mentioned about making 30s4p would need some thinking...
I would think this would need a quite hefty step-down regulator for the ~108 volt to usable in a 12 volt system.
I might be horribly wrong also!
Although this of course would minimize the needed Amperage with higher voltage.

Well yeah... my thinking on this one was way off and I misunderstood the comment.
As the commenter said, if I FIRST make 4 sets of 30 cells in parallel and THEN connect them in series, my "channels" for BMS for example drop to 4 and then are also more easily measurable with battery monitors.

My bad and now just I need to update my plans...

B: "Definitely an interesting idea. Are you perhaps planning on a 3D printed housing or what is the plan for mechanics?"

A: I'm going to use ready made holders as in and further isolate the cells with
For contacts I will be using and soldering the cells to it via individual fuses, 0.25 wire could be good, but I will need to check if it will be usable in my situation.
Soldering is not the best method, but I will clean the cell contacts thoroughly and use good flux so the heating will be minimized.

Seems to do the trick for quite a lot of people, but we will see!

I will be updating this post with further commentary and questions, so it will be up to date as best I can manage.

Sunday, September 4, 2016

Fabrication - "Racing Battery": Plans I

A long time has again passed since I made any progress in the project.
Life came in the picture as we bought a flat, I'm finalizing my degree and getting a second one, got a second dog, more responsibilities in the office and so on... excuses are many.

Now there is something that I have dabbled with in my head and decided to do a post about it.

EV and Racing batteries as in Lithium-Ion are quite interesting to me and the next step forward from AGM or Lead acid technology and people are using old laptop cells in making these kinds of batteries.
Traditional auto makers are also offering their solutions, but similar solution costs usually thousands of Euro (Porsche). This battery is going to cost me around 100 Euro, if all goes as planned.
I'm planning to make a 80 Ah battery with maximum discharge current of 160 Amps continuous and 320 Amps peak. I know this is rather overkill, but better safe than sorry!

Tuesday, April 26, 2016

Fabrication - Patch panels: Part VII

This time around I'm still messing with the left rocker panel, but some progress has been made!

As the keen eyed reader might notice, the left rocker panel is gone as a whole and so is the front corner of the rear arch.
There were three layers of metal on top of each other and all of them crusty rusty. I'm no expert, but it might not have been the best structure.

Sunday, April 3, 2016

Fabrication - Patch panels: Part VI

Well... this update is a bit more gloomier as I have realized how much there is work to be done and how much I need to learn when I'm doing this stuff.

Might have picked an easier first project!

I cut the front part of the rocker panel cleanly off as it was long gone... all battered and rusty.

Supporting tasks for the project - Garage VI and Rotisserie pick up points

I'm on a roll with these updates...

Driveline - Nissan R230: Part I

As stated in the last post, I acquired a new to me diff.

I came across a really cheap (80 euros) Z32TT R230 differential in England and could not resist so I bought it and had it shipped to me. 
I also bought two pairs of CV-shafts so now I only need the correct length drive shafts and adapters and my set up is complete (for the time being).

Fabrication - Patch panels: Part V

This update deals about what happened few (or four) weekends ago.

I continued with the upper frame by drilling 8mm holes for plug welds and then welding them up.

Sunday, February 14, 2016

Fabrication - Patch panels: Part IV

As I promised last time, this weekend I have done sheet metal work!

But first, lets do some background work for the garage.

I had noticed that the vise stand I made was not so sturdy as I had hoped.
Some rummaging later in the metal bin and I found profiles that slid inside each other and therefore I could make the system pictured here.

Thursday, February 4, 2016

Supporting tasks for the project - Garage V

I'm continuing still with garage related tasks. Next update will deal with patch panels I swear!

It seemed to me that the new work table area along with the drill press station was a little dim and this needed fixing.

Cue "China special" eBay LED-lights rated at 100w.
These units seemed rather nicely made and overall impression was nice. There has been some reviews in Youtube (link) where the ground wire has not been connected and therefore the light has been somewhat dangerous straight out of the box. This I checked first thing when I received the lights.
Fortunately this was not the case with mine as the ground wire was nicely connected to the chassis.

Sunday, January 24, 2016

Supporting tasks for the project - Garage IV

Dear Diary,

This weekend I did not weld any welds on the car or make any patch panels, but I did clean up the garage and make a new work table to replace my trusty Ikea Jerker.

Lets get it on like Donkey Kong!

First up the starting point.
Jerker full of stuff and not very much room to begin with. Also the Jerker was very flimsy in this usage... as some wiser fellow would have guessed to begin with!

Saturday, January 2, 2016

Fabrication - Patch panels: Part III

Work has also continued with the patch panels.

Here is the starting point I had before most recent repairs... Quite sorry looking sight even though quite large areas have already been repaired by yours truly.

The whole upper frame rail has to be repaired. This will be done with 1,5 mm sheet metal and lots of swearing and measuring and beating and welding.

Engine - Volvo T6 Hybridz: Part V

It has been a long time from the last update, but not a lot has happened in the project.

First of my computer acted up and still is doing so and secondly it has been rather busy in the real life!

Engine B6304F:

I started cleaning the B6304F engine off all the grime and oil by spraying mineral spirit and compressed air onto it. This worked remarkably well and also the most stubborn oil started to come off!