On this weeks Show, Jeff Sotherland was making a heater plenum for Jack's VW Thing. Being a machinist, I can appreciate how useful a tool like that would be when converting an ev but also realize how expensive and how much room a CNC milling machine takes. Since most of us don't have access to those types of tools, we need to find creative ways to sort of black smith the solutions to our problems.
When the end broke on my shifter cable, I tried to cut the nylon end in half, thinking I could slide the bushing off of the cable to allow me to drive a rod in it to make it large enough to get the cable to fully seat inside it again.
NYLON BALL RETAINER CUT IN HALF
CABLE END SHEATH RE-CRIMPED
SHIFT ROD END PROFILE
A hole, just a little smaller than the connector ball was drilled through all three bars and the ones on the outside were counter sunk with a 1/2 inch drill bit. The the inner bar had a shot put in it so it would slide over the connector ball
CONNECTOR END AND PLATE
Then the new connector was test fitted on the end of the shift cable, and disassembled again to do more fitting from looking at the marks left by the shift cable end in the aluminum bars.
NEW ROD END TEST FITTED
The new shift cable end was then removed and additional adjustments were made to the fit based on the marks the cable end left in the aluminum. After filing, cleaning and greasing the ball socket, the connector was installed.
CONNECTOR FINAL INSTILLATION
Now the gearshift was put in third gear and a pin was inserted in the alignment hole.
SHIFTER ALIGNMENT HOLE
Finally the nuts on the transaxle selectors were tightened and the shifter went through all four gears and reverse smoothly when parked with the motor not running. I was going to take a test drive to test the shifter but noticed the JLD404 was not on. After checking voltage and finding there was none, I checked the fused and found two of them blown. I had moved some wires around when adjusting the shifter and must have shorted one of them. Now that the JLD404 was back on, and the pack voltage was down to 96 volts. Below 90, the dc-dc converter drops down to 10 volts and trips the controller, so I am going to have to recharge. I had the dc-dc converter plugged into the pack all day as I was using the extension cord to operate my power tools all day, so that must have been enough to run down the module.
After working all day to make a new shift rod end connector, I was beat! For September, it sure got hot in the afternoon and I had to stop and go inside to cool down a couple times. Looking forward to charging the pack and taking the Fiero out on the road to test the new shift linkage!
Until next time,