How to Cut Myself - Let Me Count the Ways

June 16 – June 22, 2008

They say that “chicks dig scars”, so I must be a real chick magnet. I doesn’t matter what I do, working on this car has my arms, shoulders, face, legs and ankles (ouch) are battered, cut and bruised. That one bolt or nut is always in the worst spot to get to, but I will not be deterred – no matter how many times I bleed. So if your love life is lacking, just do a EV conversion and it will dramatically improve (those ER nurses won’t stay away). And just so you don’t think I’m some male, chauvinistic pig, us guys dig a scar or two ourselves. Heck, my wife just had a little wrist surgery and I can’t keep my hands off from her!

On to the car…

The battery boxes are in (the out, then in). The very front box (holds three) I figured would be a piece of cake. It sits between the frame rails and had just eight holes to drill. After a bit of cussing and discussing, it went in. After trying it with my battery models I had to figure out how to get the real batteries in – a bit of a tight fit. Next came the other front rack (a day later). Since this one was supported on the frame rails, I decided two bolts were enough. One bolt went into an abandoned hole from something I removed (already threaded and I found the old bolt!), but the other went into the frame rail itself. I wanted to hit a flange that was on top to avoid trying to get a nut and washer inside of the frame rail. I succeeded, but the hole ended up in a place that required a contortionist with three arms to get to. I only had to remove this rack once after I installed it. Next to the back where the rack above the motor was first. I did a lot of guessing when I built this rack. I knew where I wanted it to go, but it had a mind of its own. This is also the biggest rack – a four holer. When I tried to get it in, I actually did a great job of getting it stuck. I refused to undo the transmission cables, so I exercised my right to mumble a few choice words, got out the crowbar, and unstuck the beast. Reality set in and I got out the Saws-all. I figured it was safe to cut two of the braces in half and just reposition them. I got it to fit, drilled a couple of holes and marked to for welding. Once welded, it went right in. Then I noticed that one corner was unsupported, so back to the shop – it was a quick fix. As a soapbox moment, better safe than sorry. Batteries weigh a lot folks and to hit a bump and have them come crashing down, it’s worth the extra effort (and time) to do it right to avoid this from happening. If you are at a crossroads of “just git ‘er done” or doing it right, take the high road. Plus I can guarantee you that if it fails, it will damage the most expensive part – I’m off of my soapbox. With box number three repainted and ready to go, I went for the last one – a two spot in the old rear trunk. I really wanted to put the spare in the trunk, so I cut a piece of the frame off. I wasn’t structural, so I figured it was worth a try – it didn’t work, but I did save a pound or two. This rack was getting two bolts. It is supported by frame members on each end and part of the trunk lip along one side. I just had to hit the frame in the same way I did the front box. The hole ended up in a tiny corner that I could only reach with a 12” ratchet extension. I quickly got a nut and lock washer on it and moved on.

With all four racks in (and out and in) it was time to get the batteries. Getting those old batteries for cores was great - it saved me over $100. The final bill for my 12 Deka 9A31 AGM Intimidators was just over $1800. Part of the Belktronix system is a battery management system (BMS) that is integrated with the charger. Each battery has both overcharge protection and a temperature sensor. I plan on doing a religious job of breaking in my pack and taking good care of them overall. The death of many EV’s is the battery pack. Discharging them too deep and too often, over (or under) charging them and in general abusing them will kill a pack. In an overly optimistic way I am hoping to get 5-6 years out of this pack, but 4 would be great. There are tales of some folks doing this and I want to be part of the legend. And at $1800, I want to squeeze every once of life I can get from them. A BMS is the way to go and it is something you should investigate.

With batteries in hand (all 850 lbs or so), it was time to fill up those racks. I started in the front again (lots of good places to cut myself) and filled the front rack. I use a product called Coro-Plas (corrugated plastic) to line my boxes. It’s tough stuff and provides a cushion on the bottom and well as in between. I made the boxes slightly oversized to let me use the Coro-Plas and it also allows me to get everything nice and snug. Again, you don’t want these batteries moving around. One rack down, one to go (front only today). A week or two ago I was removing stuff up front when I pulled out a sensor from the heater area. I stuck in my parts box and forgot about it. Before I put the batteries in, I realized I need to put it back. I saw a few leaf bits in the hole and got out the Shop-Vac. One bit led to another and before you know it I had the entire blower system removed. It gave me a chance to get the rest of the unneeded A/C stuff out and the whole pile of leaves that were in there. Rack two was filled when I realized the terminals were not working out the way I wanted them to. The front six batteries are getting linked to the rear six to make up my 144V pack (by way of two 2/0 cables). I wanted to have a positive and negative terminal close to each other to make it easier to run these cables. Those nice and tightly fitted batteries in the lower box had to be switched around. Thank God I removed my hood from the car before I started or it would have been near impossible to get that one battery turned around. With everything in order, I got the other three batteries in place and packed with Coro-Plas. Adding over 400 lbs to the front of the car certainly lowered it. There is still a little spring left in the front springs, so I don’t think I have bottomed out yet. I will have to wait until I get a chance to drive it before I see if bigger springs (or air shocks) are needed. I am going to wait on the wiring until I get everything ready – having 72V (or 144V) just waiting to zap me is a scary thought. I one time arc welded a Seiko watchband (while on my wrist) across two alternator terminals at about 14V – 144V would really hurt (but just think of the scar).

In the back I had some old ICE wiring to deal with before putting in the batteries. For now I am zip tying them up just to get them out of the way. I figure that if I need something later, it would be easier to deal with still intact. But just to make the back of the car less jealous, I made up my jumper cable for my motor. That pretty, green 2/0 cable across the A1 and S1 terminals is just the start to the wiring nightmare that awaits me, so I better get some sleep. So until next week….

I've been framed...

June 9 – June 15, 2008

Strange week… I had some training at school to do this summer with occurred on Wednesday and Thursday. I was tired of trying to get my lab clean so I took Monday and Tuesday off to work on the Fiero. Plus, two of my ordered items were coming at the beginning of the week and I did not want to miss them.

In preparation to doing the battery boxes, I figured I needed to get some cable for the batteries. I checked with Belktronix (Bryan) for his recommendations and he suggested 2/0 welding cable. I checked Ebay and saw quite a few, but as you know, bidding can get crazy. We have a big welding supply shop in town, but they did not carry cable in bulk. Strangely enough, one of the ad sites on Ebay sent me to http://www.weldingsupply.com/ and they are great. Not only are their prices good, but they also had crimpers and lugs real cheap. I ordered enough cable to do what I think I need to do and have a plan to make my own connections – we’ll see. That box arrived two days later as did my first box of electronics from Belktronix (controller w/fan, system integrator module, pot box and contactor). Lots of cool stuff to look at! Back to the battery boxes. The same person who suggested the bed frames also mentioned the hardness of the steel – it’s hard. I killed a Saws-all blade in about 15 seconds and went to plan “B”. I bought a Roto-zip several years ago and it has seen its share of jobs. I came with a metal cutting disc and it cut right through the bed frames. The only problem was I got 4-5 cuts per disc and I had a long was to go. I checked Lowe’s for replacement discs, but at $2.50 each, I went to Harbor Freight. I got a 10 pack for $6.00 and only had to open up the hole a bit to fit my Roto-zip. I got just as many cuts for a fraction of the cost – yeah Harbor Freight. Because the batteries are common sizes, I was able to figure out one box and reuse the dimension – just change the configuration of the box. Two bed frames proved to be just right with a little left over. Four battery boxes made for less than $30.00 and some welding time. I did most of the welding before my training at school. I added hold down tabs (1x1x1/8” angle) to each box as well as mounting pieces out of 2” x 1/8” flat stock to attach them to the car. I had to guess on the box that fit above the motor and it required a slight modification. I gave them a quick paint job to keep them from rusting (I plan on finishing them in flat black) since they are living on the back porch. I hope to have them installed next week.

I also had a chance to finish the plug installation. I found a piece of 3/8” Delrin plastic and made an adapter to mount the plug to it and also it to the car. When I cut out the gas filler tube, I made the hole too big for the plug to just fit in, so I had to make the adapter to clean things up – looks pretty good if I do say so myself. I reinstalled the door and I only need to remove the “Unleaded Fuel” sticker. Another side project involved installing a rack/spoiler on the Fiero. I purchased a used trunk last year that had the rack on it. My plan was simple – swap them out, but so much for a simple plan. After changing hinges and a louver, I noticed a crack in the new trunk lid. No biggie until I saw the other crack on the opposite side. I checked my old one and it was good. I removed the rack from the used trunk, measured, drilled and installed it on my trunk and a few hours later, I have a rack/spoiler. Now my trunk is heavier and does not want to stay up, but I’ll figure it out!

So on the slate for next week… Install battery boxes, pick up batteries and install them, install cables and assorted hardware/electronics. Heck before you know it, I’ll be driving it. Until next week…

What a Week!

June 2 – June 8, 2008

I am going to add another day to this week’s blog because I just do not want to wait another week to update what I did today.

I did spend the week cleaning my lab at school and did not finish it, but that is what summer is for – I’ll get it done. I think it was Tuesday that I was talking with a friend about batteries and he told me he had a stash of dead (and I mean dead) back-up batteries from several systems he had been working on and I was welcome to them. This just solved my core deposit problem. I loaded up my truck they are now awaiting a trip to my battery dealer so I can order my traction pack – twelve, 9A31 Deka Intimidators! In preparation for installing my 12 pack, I made up six battery models to test out configurations in the car. My plan was to always do six in the front and six in back. I looked at several other Fiero set ups, but a lot of them used 6V batteries and managed to get 20 of them stuffed in there. My 12V, 12 battery pack was never intended to be a long distance conversion, so I gave up the few extra miles for the weight savings – and we are talking about 200-300 pounds at least. One thing I did not want to sacrifice was my spare tire and what little storage space I have. The spare usually fits up front, but it is going to the back. I have it crammed between two of the rear batteries in what used to be the rear trunk. If I ever need it, I will have to pull those batteries, but at least I will have it. The other four batteries fit neatly above the motor with room to spare on each side for the electronics. I only had to remove one small bracket in the rear to make everything fit. Up front was a different story. I knew things were tight before I started and it would require some cutting. Since I have opted to do without A/C, those things could be removed to make room. The low hood also made it challenging, but thanks to my Saws-all and sacrificing part of the front trunk, I have room for three batteries now. The other three went where the radiator use to be. I was a little concerned putting them that forward, but upon further review, there is a frame member that cages in those batteries and lots of contact points to attach everything. So as it stands, most of the weight is above the axle/wheels and for the better part it is balanced (6 front, 6 rear). I hope this also improves the Fiero’s handling – we’ll have to wait. I picked up another bed frame today and will start cutting and welding next week.

The other great news is part of my first electronics order has shipped. It includes my controller, throttle box, main contactor and system integration module. It’s a start and I can get started with its installation along with the batteries. I can feel that EV grin starting up as I write.

I fixed that leaking transmission seal. I had to take most of the passenger side apart, but it wasn’t that bad – maybe an hour. It’s to the point that I now know more about the rear end of a Fiero than I ever thought possible, and am glad that I do. And for all of you out there thinking about doing a conversion, don’t fear what you don’t know. I have done a lot of car stuff during my life, but nothing like this. Just some basic tools (socket set, combination wrenches, screwdrivers, a hammer or two) and a desire to finish what you start and even you can do it. Time is on your side when you do a conversion because you always have to wait for something – and this can be a good thing. Take time to plan what you are doing and always take the opportunity to fix things as you go. Enough of my soap box time.

Finally, I ripped (cut, destroyed) out the old gas filler tube to make room for my battery charger connection. I found a three pronged, 20A twist connector and plug at one of my electronics surplus stores in town and it’s a perfect fit where the tube use to be. It was a fight getting it out, but well worth the trouble. When done I will be able to use the current door (with lock) to hide my secret plug connection and it is just a few inches from where I plan to install my charger unit – life is good.

So until next week…..

The School Year is Over!

May 25 – June 1, 2008

The last week of school leaves nothing it terms of spare time. Give a final, grade a final, enter final grades into the computer – repeat. Add to that a monster student project and the week was shot.

I guess the best thing about a shot week is the opportunity not to work on the car. This blog has attracted a few other converters and it’s been fun emailing back and forth about my project and what they are doing. I read about a guy who used old bed frames to make his battery boxes, so I was checking out the local Goodwill store and found one frame for $5.00. If I bought the same amount of 1-1/4 angle iron it would have been $15-20 – thanks for the tip whoever you were (EVDL). Another fellow EV’er, Brian, is doing a Fiero also. I shared with him some adapter plate info that I hope will work for his V-6 Fiero (mine is a four cylinder). And I met another guy in Ohio that has used the Belktronix system I have ordered. So even when I am not working on the car, I am still learning and sharing – and that folks is what it is all about.

I almost forgot the only work I did do was to refill the transmission. As you may recall, when I bolted my adapter plate I realized that it was now stuck and I had to pop out the other CV joint to get it out. I figured that the seal would survive such a little movement – I just slipped it out and shoved it right back in. Guess what seal failed when I filled the transmission? Not only do I get to replace the seal, but I get to clean up all of that fluid. I am hoping I do not have to completely disassemble that side of the car, but with my luck, I will.

Next week I get to spend most of my time cleaning my lab at school. So it is going to be another slow week… so until next week…