TGIF

A day of vacation was taken today to take my wife to the doctor in the morning, then to the pharmacy and back home to meet with a contractor to get an estimate on new counter tops for the kitchen and bathroom. Then off with my sister to help her purchase a car.

Between all of this, the vacuum pump was wired up and tested out fine and the Fiero was jacked up and the cables from the front compartment to the motor bay in the rear were removed. Next some uni-strut will be installed in the tunnel, the cable will be run through the flexible conduit, and the conduit will be fastened to the uni-strut. The last task under the car will be to cover the tunnel with aluminum sheet, to help keep the moisture out. Then the two modules will be able to be connected together.

It was my hope to get more done but sometimes that just doesn't happen and at least I did get something done. Hopefully there will be fewer distractions tomorrow but for now; Thank God it's Friday!

Randy

HERE COMES THE SON

My son had not been over for awhile and was taking a half day off work to take his cat to the vet, after which, he was stopping by the house. We haven't seen him much during the summer and he had to leave around 6 pm to go look at a house, so I decided to take a half day off of work also, to spend a little time with him. 

I had a new mirror ordered for the bathroom and Chesshir Glass emailed and said it was ready, so went and picked it up. When I got back from picking up the mirror, I took the cover off of the bathroom fan to get measurements, then got on the Home Depot website and ordered a new fan and lights for over the new mirror.

With some of the household chores out of the way, it was time to finish adjusting the parking brake. After a couple of tries at setting the parking brake, it was finally adjusted so it worked well.

PARKING BRAKE ADJUSTER

Then it was on to remounting the vacuum pump for the brakes. A place on the front wall of the front trunk was found and the bracket was mounted in place. After a little moving the hoses around, the vacuum lines were made up and the electrical connections are ready to be hooked back up. This would have been done but a storm was rolling in and there was lightning all around, so I packed it up and well hook the vacuum pump up later tonight or tomorrow after work.

VACUUM PUMP MOUNTED AND HOSES ROUTE

Maybe another post tonight and maybe not until tomorrow but the Fiero will be ready to test drive soon and if the brakes feel good with the vacuum pump hooked back up, work will begin on connecting the second module up.

Thanks for visiting,

Randy

GIVE ME A BREAK.....PARKING THAT IS

After the new brake line were run, when I got home, the parking brake would not work. Tonight I finally crawled under the rear of the car and found that when the brakes were being adjusted, the nipple had pulled out of the holding bracket. 

The bracket was removed and the threads were cleaned with a wire brush, then the nut was heated with a propane torch and worked back and forth a few times to free up the threads. Then the threads were sprayed down with some WD40 and the nut was run out almost to the end of the threads. The ends were installed back in the bracket and will be adjusted tomorrow after work.

NIPPLE OUT OF HOLDING BRACKET

BRACKET REMOVED

CLEANING THE THREADS

REASSEMBLED

I don't think Gary, my mechanic over in Kirkersville, OH realized how important a parking brake is on an electric car, as there is no engine compression to hold the car when it is parked. The holding bracket was a little damaged but I am going to try to put some weld on it to bring it back to working condition.

Until next time,

Randy

NO ACCESS DILEMMA

The holes were drilled yesterday for the liquid tight conduit connectors but there was a dilemma; How could they be pushed in from underneath the car, when there was no one on the top side to install and tighten the conduit nut? Alright, I have a plan, a piece of threaded rod will be dropped through the hole and there happened to be a large washer with a small hole that could be installed on the threaded rod to hold the conduit connector. After a bit of crawling around on my belly like a reptile, it worked like a charm!

WASHER AND NUT ON THREADED ROD

CABLE CONNECTOR WITH CONDUIT NUT INSTALLED

With the spring spacers removed and the battery module installed, the front of the Fiero came down an inch or so, making it a little hard to squeeze under the car without hacking it up, so a board was placed under the front bumper, relieving the spring tension just enough for me to slice under the car. I wasn't worried about it slipping out because the car was high enough with out it that it could not come down and smash me.

  

RELIEVING TENSION ON FRONT SPRINGS

Not much progress, but progress, and after this weekend, I really need a little break, so back inside to watch this week's episode of EVTV.

Thanks for dropping by,

Randy

BUT WAIT...THERE'S MORE!

This has been a busy weekend, as I am getting ready to paint the bathroom and re-grout the tiles, so I needed to make as much progress as possible on getting the second module connected. July is almost history and EVCCON is only 8 weeks away. It seems like there is so much to do and so little time.

The module connections were installed, then the next project was to drill holes in the deck plate for the cables to be run through. There wasn't much room in front of the module but I was finally able to get into a position to center punch the locations and drill the holes with a hole saw.

BATTERY CONNECTIONS INSTALLED

HOLES DRILLED FOR CABLES

Earlier in the day a trip was made to ACE Hardware to pick up some flexible conduit and Liquid Tight Connectors to run the cable in.

3/4in x 25ft Ultratite Flexible Conduit

3/4 IN LIQUID TIGHT CONNECTOR

So the end to a busy weekend, that started with mowing the lawn on Friday, finishing some touch up painting around the new patio door and purchasing a car on EBAY, then working on the battery module. My work cloths still need dried and hung up but tomorrow back to work, so maybe I can get a little break and rest up a little!

Until next time,

Randy

ZINC PLATING

After test fitting the battery connections, I was just dying to try out the zinc plating kit that was purchased from Eastwood sometime back. After cleaning the copper bars until they looked clean, then cleaning them again, the solution was pored into the plating container, batteries were installed in the holder, the zinc bar that was supplied with the kit was hung on the side of the plating container with the positive lead hooked to it, the negative lead was connected to the copper bar which was immersed into the solution. After about 4 minutes, the bar was removed revealing that a thin coat of zinc had been plated on the surface.

EASTWOOD ZINC PLATING KIT

PLATED COPPER BARS

The plating worked very well and should give the connections a sacrificial barrier to prevent corrosion. 

Electroplating System Tin Zinc

Item #10049Z

Thanks for visiting,

Randy

MAKING NEW CONNECTIONS

Over the last three years since the Fiero was purchased and I started my journey into electric cars, many connections have been made through EVTV, DIY Electric Car, Youtube, Google Plus and this blog. Many of the ideas used on the Fiero conversion, have come from the suggestions of other builders and much help has been provided from the local builders, that are part of these connections.....But wait, that is not what this post is all about!

This morning work was started bright and early on making up the second module connections so it can be tied to the first module. Fortunately a large cache of copper and aluminum bars and angles have been built up since the conversion started, not to mention all the fasteners left over from other projects, so I started scrounging around the garage, to find all of the materials needed.

COPPER BAR IN VICE

BENT COPPER BAR

CONNECTION TEST FIT

The two half modules need to be hooked together at the other end, so I decided that would be a good location to place a fuse. I had the one that was on the car when I originally purchased it, so decided to try and find a way of mounting it between the two half modules.

FRONT MODULE FUSE TEST FIT

Alright, I have had my little coffee break and satisfied my craving to do a blog post, so BACK TO WORK!

To be continued,,,

Randy

THE EAGLE (BATTERY MODULE) HAS LANDED

  

LANDING MODULE

Ok, it's not bolted in but after working for the last month to enclose the front trunk and reconfigure the battery module, it is finally sitting on the deck plate! The connectors still need installed, the cable run through the deck plate, and a couple copper bus bars to connect the packs together and run to the new terminals but I feel I am on a roll. A couple of cable glands may need to be ordered but it shouldn't be long until some range testing can be done.

MODULE IN FRONT BAY

Enough for now as I am headed back out the the garage to continue working on connecting the module.

Thanks for stopping by,

Randy

MORE PROGRESS ON BATTERY MODULE

This week the other two end plates were cut out and the terminals arrived from EBAY, so with any luck, the second battery module will be ready to install this weekend.

END PLATE WITH TERMINAL

ALUMINUM ANGLE HOLD DOWN

Finishing the calking and trim painting of the patio door off of the dining room has been taking up some of my time but was finally able to get a little done on the Fiero this week. The weather is supposed to ge great this weekend, so hopefully I will be able to get the second module installed in the car. The voltage on the second module will need to be matched with the first module, then can be connected together. 

Thanks for visiting,

Randy

SECOND BATTERY MODULE MOUNTING PREPARATION

Thursday evening I took a trip to ACE Hardware and picked up some thin steel plate, fasteners, and 12 in lengths of 1/4 in threaded rod. I had made a template of the battery module end last week and used the template to make two steel end plates. After the end plates were cut, drilled, and fitted, the strap holding the half module was loosened enough to slide the plates onto the ends and the threaded rod was inserted through the holes on each corner. Then a large clamp was used to compress the half module enough to get the nuts started on the threaded rod. There is a bit of a recess on the edges where the threaded rod comes through the end of the module, so the hardest part of getting everything bolted up was getting a 1/4 in washer behind the plates, so the plate would seat nicely on the end of the module. 

STEEL END PLATE BOLTED TO MODULE

There will be an insulated terminal bolted to the steel plate and a copper bus bar will be bent to connect the battery terminals to the terminal on the end  plate. This will be where the cables going to the rear pack will connect and a hole will be drilled between the battery terminal and the insulated terminal to connect the third module, that will be mounted in the front area where the radiator used to be mounted.

Aluminum angles will be drilled to bolt to the bottom threaded rod on the modules, then will be bolted to the deck plate that was just installed. I may put a piece of rubber sheet under the modules so they will have a little padding, instead of just sitting on the deck plate.

EXAMPLE OF ANGLE MOUNTING

Tomorrow I am going to calk and finish painting the outside of the new French Patio door I put in last weekend and will probably do some touch up painting around the inside molding but then plant on going back to ACE Hardware and picking up some more 1/4 in threaded rod to get the other half module ready. I am also going to need to order some more insulated terminals, as it seems all of the ones I had, have already been used.

It is a little exciting as the second module will allow me to drive the Fiero to work, so once the module is installed, I plan to drive the car into Columbus, OH on the weekend to test it. There is a public J1772 charger about 11 miles from home, so if it looks like I am running out of juice, I can stop there to put enough charge in the modules to get me home.

Thanks for visiting,

Randy

TEN THOUSAND PAGE VIEWS

It's amazing that over the three years that I have been rebuilding the Fiero, there have been 10,000 page views from all over the world. This blog is really what keeps me motivated to go out and keep working on the conversion to lithium batteries, even when I am not feeling well or my heart is really not in it. I find that after getting started on a project on the car, I become rejuvenated again and enjoy working toward getting the car ready to be able to drive the 25 miles to work each day.

10,000 PAGE VIEWS

ALL TIME BLOG STAT

PAGE VIEW MAP PAGE 1

PAGE VIEW MAP PAGE 2

This week also marked the first test fit of the second battery module, which will give the Fiero enough range to get to work and back. If I can get access to a charger at work, then using the Fiero to commute is 100% possible.

Thanks to all of you who have been following my build and as always, drop me an email from time to time to let me know how your builds are going.

Thanks for visiting,

Randy

FRONT BATTERY MODULES

The Fiero spent three days at Gary's Place Garage, last week getting new brake lines run and having the front spring helpers removed. On Sunday the deck plate and front sheet metal were installed and the split battery module was placed in the front for fitment.

FRONT BATTERY MODULES

After some more fitting, the Fiero will be taken back over to Gary's Place Garage to have mounts fabricated, then the front modules will be connected to the back module. This should give the Fiero a solid 40 mile range with the possibility of up to a 58 mile range.

Until next time,

Randy

THE BEST LAID PLANS OF MICE AND MEN!

Work continued on the front trunk enclosure on Saturday and the cross members, wheel wall, firewall and deck plate support angles were coated with etching primer, then painted satin black. Everything was rolling along nicely and the only obstacle left was one brake line that still did not fit into the channel that had been cut in the support angle. After several attempts in straitening it out, I finally came up with a plan to clamp the bend between two blocks of wood and hopefully, when the c-clamp was tightened, the tube would straighten out enough to fit. With the clamps in place, tightening began and the tube began to bend back where I needed it to be, success was in sight! With the tube almost there, I took another couple turns, with resistance starting to increase, then there was a squirt and my hand became drenched with brake fluid. Oh well, just one turn too far. I guess it is better to snap the line now that to have it break when I am on the interstate going 70 mph, so went in the house and called a local mechanic in Kirkersville, OH. We talked for a few minutes and he agreed to put new brake lines on the car next week and then bleed the brakes after they were installed.

BRAKE LINES

DECK PLATE AND SHEET METAL FINAL PREP

With the car going to the shop next week for new brake lines, focus will turn to getting the battery pack ready. The pack will be split in half and each half pack laid flat on a plate with four pieces of all thread attaching the cells to the plate. A mount will be bolted to the fender wells on each side to bolt the module plate firmly to the car.

SECOND BATTERY MODULE

BASIC ARRANGEMENT OF NEW MODULE

Thanks for visiting,

Randy

HAPPY 4TH OF JULY!

Where did the time go? We are over half way through the year and EVCCON is less than 3 months away, leaving me with quite a bit of work to finish if I am to take the Fiero.

After arriving at work last Monday, it was really difficult to keep my mind on the job, as I had basement windows being installed in the house and needed to work on getting a new patio door, in addition to wanting to work on the Fiero, so took the remainder of the week off on vacation.This was a good move as I was here to make a few decisions on the window installation and also was able to find a patio door, and have it pre-painted, sitting in the garage, waiting for my son to come over next Sunday to help me get it on the back porch. Our car got a good interior and exterior cleaning and some Roundup was applied to all of the weeds in the driveway and around the house. It is funny how things just creep up on you and the next thing you know there are a million small chores that need done around the house. Well this week gave me a chance to get caught up a little. The down side is I will have to pay for it when I get back to work on Monday, as I am sure I will be swamped!

NEW PATIO DOOR

NEW BASEMENT WINDOWS

Finally on Thursday I was able to get back on the Fiero by making a template for the front sheet metal to enclose the batteries. After several attempts, the basic contour of the sides of the engine compartment were transferred to the template and I found that when reversed, the template was the same for the driver's side as well. Friday morning work continued on the front enclosure and the end template was fitted on one side, then a mark made on the front hood seal sheet metal, then fitted to the other side and another mark made on that side. Then a measurement was taken between the two marks and a full template of the sheet metal cover was made.

END TEMPLATE

FULL FRONT PLATE TEMPLATE

After a final trim, the template was transferred to a piece of aluminum sheet and was cut out with tin snips. After dressing the piece up with a file to remove all the sharp edges and burrs, it was fit into the front compartment and self tapping pan head sheet metal screws were used to attach them to the existing hood seal sheet metal.

FRONT SHEET METAL IN PLACE

In the picture above, the sheet metal is being fastened to the aluminum angle that goes across the front. The front sheet metal will be removed to get the deck plate in but the screws will line everything back up, as the front angle will be held in place by screwing it to the deck plate on each end.

When the sheet metal is removed tomorrow, the angles will be sprayed with etching primer, then black bed liner paint and hopefully I will have pictures of the finished enclosure to post.

Until Tomorrow,

Randy