Final Parts Dribbling In

When I got back from my trip to Infineon, I had a small box from ElectroAuto waiting.  Inside I found:

The lug crimper.  I'm not going to use this because the hydraulic one I borrowed from Kelly is far superior.

The contactor diode.  I can't find anything in the instructions that says which terminals to attach this to on the contactor, so I'll have to do some research later.

Positive and negative terminal posts.  The electrical system design uses these posts to be the main mounting points of the positive and ground parts of the circuit.

Battery box weather stripping.  This sticks onto the top edge of the battery boxes and seals out the elements.

Wiring harness.  This is a pre-built harness to accelerate the process of hooking up various electric bits.

This means the very last parts I'm still waiting for are the hood pins!  I also realize now that I'm at the point of wiring up the high-current DC cables, that I'm missing a copper piece that goes between two posts of the electric motor.  It's a flat copper bar with heatshrink tubing shrunk onto it, with a hole drilled in each end.  I emailed Shari that I didn't realize I was missing this part because it's not explicitly listed on the shipping list.  Of course I didn't get a reply, but I'm hoping it will just show up some day.  Worst case I can fabricate it myself.

Racing 914 at Infineon Raceway

I was up at Infineon Raceway in Sonoma, California to finish up the solar power monitoring system on Thursday and Friday.  Among the amazing exotic cars was this tricked out 914.  The owner said he pulled the original engine and put in a 400+ HP Subaru WRX motor.  It went in nicely because it's smaller than the original and weighs only 25lbs more.  Enjoy.

Warbirds, Wings and Wheels 2011

The Estrella aviation and car museum in my town has begun to host a car show every spring.  I attended for the first two years, but this year I decided to enter my in-progress car to enjoy the experience and talk with people about electric cars.

I had to re-attach the wheels, drop the car off the jackstands, winch it up on the trailer, drive it over, maneuver it into position, winch it off the trailer and roll it into position with no steering wheel.  Setup officially opened at 7AM but I didn't get there until about 8, and the place was virtually full.  I had to park way out at the end, but it was a good location because people seemed to do a loop down the main road and back again, and I was at the far end of the loop.

As you enter the grounds, they were taking pictures of each car.  Here's mine, not the most glamorous shot, but you can see the potential...

This was the main row, with the limit of 300 cars packed into the airplane display area.

Here is the car in position, with an informational sign I made and had laminated and the battery boxes sitting in place.  The electric motor was in plain view and was a good conversation starter.

I really lucked out later in the day when this rare and beautiful Jaguar XK120 parked next to me.  The restoration was impeccable and both cars had nearly the same dark gray metallic paint color.

I talked with at least 50 people about the car and electric cars in general.  The most popular question was, of course, how far can you go on a charge.  Most people seemed happy with the expected 60 mile range, only one person said they needed to go further than that each day.  I think that's a pretty good statistic for the potential for widespread adoption of electric cars.  Most people were very surprised that the car can go 85+ miles per hour.

Next year I'll definitely enter the car again and get it there and back under its own power.  Thanks to everyone who stopped by and took the time for great discussion.  To the person who stole my car polish, microfiber cloths, winch gloves, car exhibitor goodie bag and $40 quart of POR-15 - I hope you die of syphilis.

Firewall Reshaping

The middle battery compartment fits in where the gas tank used to go, between a vertical wall on the front trunk side, and the firewall on the passenger compartment side.  Unfortunately to fit the battery box in place, you have to "reshape" the firewall.  In fact, it's bashing as hard as you can.  I hated to do this to my new paint job, but I didn't know how to shape it when the car was in the body shop because I didn't have any parts yet.  Did I mention that EA has been tardy delivering my parts?  :^)

So here I am, bashing the firewall into shape.  There is a support bar underneath the steering column that makes for very, very hard bashing, so I crawled into the passenger compartment and cut a section of it out with my angle grinder.

Here is the progression of the bashing and the start of the bondo to leave a nice shape.

I've got the car entered into the Warbirds, Wings and Wheels show this coming Saturday at the Estrella Warbirds Museum at the Paso Robles airport.  I need to get this smoothed out, primed and painted to be ready.  I'll take it over on the trailer and get it in place in time for the start of the show.

Finally Some Electrical Bits!

Now that I've got my remaining electrical parts, I can get started.  I can't do the whole job yet because I'm searching for some "affordable" plastic boxes to hold the contactor, potbox and terminal blocks.  I'm not leaving those out to the elements as the EA manual says.

Anyway, I was able do get started.  This is the supplied DC high-voltage, high-current cable.  It's called welding cable or locomotive cable, and is made up of hundreds of hair-sized wires, so it's very flexible.

EA is supposed to supply a cable lug crimper, but it hasn't shown up yet...  I checked around at work with the electricians I know and found that Kelly Minton has a great hydraulic crimper.  You can see the steps to make a solid crimp below.

You can see the crimper crimps from 4 sides for an extremely good connection.  The final step is to put some shrinkwrap tubing and shrink it down.

I mounted the controller to the backing plate.  This was heavy and messy due to the white heatsink compound.  I built cables and mounted to the controller and the motor.  The rest will come in when I mount the contactor in the box.

I Saw A Leaf Up Close Today!

My biodiesel club had a spot at the San Luis Obispo Earth Day event, so I drove down in my Beetle TDI and set up to discuss biodiesel with the attendees.  I was parked in the alternative vehicle area along with a CNG Honda from Funride, a Honda CRZ hybrid and then up comes a Nissan Leaf!

It's bigger than I thought it would be.  The styling is great and there's lots of room inside.

The owner has had it for about 3 weeks and has driven it for 300 miles.  No problems at highway speed, going up hills, or handling.  It has the J1772 plug, plus a high-current DC charging plug widely used in Japan; hopefully it will become the DC standard over here.

There's a large multi-function display inside and a small joystick that controls park, forward and reverse.

The owner said he's received notification of a software bug fix.  The battery monitoring system sometimes switches into safe mode and won't restart when the air conditioner is turned on, giving a spike in power draw.  A small setback in what is otherwise a great project.

and More and More Parts

As a result of my threatened visit to the EA seminars or EA's improvements in cash flow, I got a flood of parts which is nearly everything I need to complete the job.  Here is the 120V AC - 120V DC charger.  If I find that 120V charging takes too long, I may buy a 240V AC charger and wire them in parallel.

Here is the contactor:

Here is the DC-DC converter.  It takes a feed off the battery pack and provides 12V to the existing systems in the car such as lights, radio, etc.

Now all I'm waiting for are the wire crimper, terminal blocks, battery box weather stripping and hood pins.  I don't know when these will arrive, if ever so I'm going to buy them from other sources so I can continue the project.

We're Suspended

It took the better part of 3 weekends to tear the suspension apart at each wheel, rebuild and reinstall.  The first thing I want to say is that EA's manual references the Haynes manual to take apart the front suspension.  It involves taking the brake caliper and the the hub off which exposes the wheel bearings.  If you have a deep desire to check wear on the bearings it's a good idea, but it's unnecessary.  It was much heavier to keep it all assembled, but with the aid of my floor jack it was much easier to do the work on the passenger side than the driver's side.  Anyway, let's dive in.

This is the driver's side, I removed the brake line (and didn't do a very good job of containing the brake fluid) and pulled off the previously-upgraded BMW brake caliper.  I checked the pads carefully and they looked almost new with lots of material left.

Then I took off the hub nut and pulled the brake disc and the brake disc cover.  The ball joint on both sides was in excellent condition.

When I got to this place, I noticed that the tie-rod end's rubber boot was shot, so I ordered two new ones from Pelican Parts.  Here is the old and new:

I unbolted the top of the strut from the inside of the front trunk, pulled the strut down and levered it out of the fender.

Here are the old and new struts.  The old ones were shot - you can see that when the arm is pressed down into the body, it doesn't pop back up again.  They needed to be replaced anyway.

There's a rubber bumper-stop located at the top of the strut body.  Both sides had one of the three lobes badly disintegrated.  I searched far and wide on the web for replacements, to no avail.  I stopped in at SGS Motorsports (formerly Strasse) in San Luis Obispo and asked the expert there.  He said unless the car had been lowered in the past, it's safe to just cut off the bad lobe.  It's meant as the final protector when the car completely bottoms out.  So here are the before and after:

Next I moved on to the torsion bars.  In this car, the torsion bar slides into the long tube at the bottom of the suspension A-arm.  This is different from my Nissan pickup where the torsion bars are exposed and mounted rearwards of the front suspension.  Here are the old and new, and you can see the difference in thickness, which is needed with all of the extra weight.

Here are shots of the front and the rear torsion bar mounts.

Here is the A-arm, pulled from the driver's side.  You can see the collection of tools it takes to get the job done.

Now comes the hard part.  Getting the rubber bushings out of the A-arm was a huge pain.  They've been jammed into place for 38 years and I had to use two different puller tools and a lot of lubrication.

Now I moved over to the passenger side, taking the whole suspension out without tearing the caliper, disc and bearings apart.
 

Getting the torsion bars in and out was easier on this side for some reason.

I cleaned off all of the gunk, then sanded off all of the rust down to smooth shiny metal.

And now everything is back in.  It doesn't look like much, but we've got new torsion bars, new torsion bar bearings, full lubrication, new struts, cut-down strut bumpers and new tie-rod ends.

I then polished the strut-top hardware and bolted everything back in place.

Now moving to the back the job is a lot easier.  The new shocks and springs are near total replacements, but there is some hardware that needs to be swapped over.  I can't do this job myself, as the spring has to be compressed and bolted on to the new shock, so I took it over to Morin Brothers and they got it done in less than an hour.  The new assemblies went in smoothly.

Whew!  A lot of work for no real visible improvement, but I tend to focus on infrastructure so it's rewarding to me, and now the car will support the rest of the effort.

My Second Visit with Electro Auto

I'm sorry this post has taken a long time to put up, but my visit with EA was followed by a two-week solar monitoring installation trip to Infineon Raceway in Sonoma, north of San Francisco.  Then it took about two weeks to catch back up on life.

My visit was a direct result of the poor communication and broken promises I've experienced by EA.  As you can read in previous posts, I've been waiting for about 9 months for a significant number of expensive parts and have had no luck getting any kind of response to my calls and emails.  An alert reader pointed out that EA was beginning to hold monthly electric car seminars in San Jose.  I emailed EA that I was going to drive up on the day of their March seminar and tell their attendees what kind of business they're running.  I also wanted parts or the cash equivalent refunded so I could buy them from other suppliers.  I also threatened to take them to court.

This got a response from Shari:

"The seminar would not be an appropriate time and place for this discussion.  When we are doing a seminar, our mental focus is completely on that course material, and even the "break" times are pretty much filled with answering student questions."  "The past couple years have been extraordinarily brutal, financially.  We went from $xx gross WEEKLY sales to the same amount as gross QUARTERLY sales.  We went from us plus a staff of 3 full timers and 5 part timers to just the two of us.  From what we hear from our suppliers, our situation was not unusual during this difficult time.  Finally, this spring, we are seeing signs of recovery, and we are pursuing every avenue of cash flow we can find in order to get caught up on our obligations, able to carry inventory, and to deliver promptly.  I believe we can be at that point this summer."

Then a flurry of parts started arriving, including the struts, shocks, springs, torsion bars and bushings, charger, DC/DC converter and contactor.  Maybe they were reacting to having income from the seminars, but maybe I was just the squeakiest wheel and I could affect their business by protesting in front of the following seminars.  I decided I was still going to go and told Shari by email.

On the morning of March 19, I left home around 6 AM and arrived at the seminar location in San Jose at about 9:30.  Nobody was there yet so I waited in the rain outside the building.  After a while I saw Mike from EA park and start walking towards the building.  He saw me and then recognized me and nearly stopped in the street, but kept walking to me.  Now I'm going to try to describe our conversation.  I'm sure won't get it exactly right, so any mistakes are mine.  You'll get the gist of the discussion.

I said "Morning Mike, remember me?"  He said he did and immediately got very defensive.  He asked me what I wanted and I said I wanted the rest of my parts for the car.  He said I just got a big shipment of parts, what was I doing there.  I explained that I hadn't had any email or phone calls returned in months.  He said, literally, "What do you want me to do, slit my wrists?".  I said of course I don't want that, but I do want you to understand that you owe a lot of people parts that they've paid for and haven't received.  He then said "Who made you God?".  I tried to stay calm and factual, so I said "Of course I'm not God, but a lot of people have contacted me because they are waiting for parts too."  He then started describing their financial problems.  He tried to get me to understand the difficulties of running a small business.  He asked me what I did for a living and I told him I was an engineer.  He then asked if I ever had to make a payroll and I said yes.  He then looked at me like I've been through the same kind of situation.  They have had some very bad problems due to the economy and a big drop in orders, but now with the seminars they have money coming in and are working to ship the backlog of waiting parts.  I said I'm happy that things are turning around, but you have a lot of very unhappy customers out there.  He told me a story that one of his former employees told him he was a "shitty manager", and it's hard to run a business if you're only good at building car designs.  I agreed that it's hard to be good at many different things, but I thought that Shari was handling the business side.  He just sighed.  He completely changed his attitude and seemed like all the air had come out of him and he was beaten down by the circumstances of the last year or so.

I then tried to take a different tack and said that as long as parts were flowing again, I would suggest that he work on communicating with his customers.  Return emails promptly and completely, answer the phone and tell the truth.  I pointed out the phone number listed on the web site wasn't correct and Shari's packing slip emails actually say

" If you have any questions about your order, please contact Bill Lentfer at bill@electroauto.com or 831-251-8656. He will get back to you by the next business day at the latest."  

The problem is Bill doesn't work for them anymore and doesn't respond at all at that email or phone number.  They need to correct everything and go back to notify all customers what the status of their parts is.  I asked him why they didn't simply answer the phone.  He mumbled something about "You just don't understand".  I later realized that they were probably getting calls from collection agencies and other nasty people and were

I said that I hoped I had helped him understand what he was putting his paying customers through, and to ship parts ASAP and stay in effective communication.  He thanked me for having a calm conversation about the issues and admitted when he saw me standing on the sidewalk "you scared the shit out of me."  I told him I was sorry that it had come to this, but I ran out of options, and I was lucky that I was within driving distance, something that many of his other customers didn't have the luxury of.  We shook hands and he went inside and I got in my car and drove up to start on my solar installation.

I'm hoping that other people have been contacted or have had some parts show up.  I know one person making one visit isn't going to change the world, but I hope it had some small effect.  Please let me know if you've been contacted or received some parts in the last month or so.  Fingers crossed!