The design for the adapter is done. There are actually 3 components: The adapter plate, motor hub, and spacer ring.
The design's been sent off to the machinist. If all goes well, the parts will be here in 4 weeks.
Flywheel Removed
Sunday, May 24, 2009 by EV Hacker
I was finally able to remove the flywheel today. There's a big 54mm nut torqued down rather tightly holding the flywheel on the shaft. When I looked for a socket in the past, they were around $50 (!). Today, I found a 2-1/8" socket for $28 at Sears that should work. I'd purchased a cheap little Harbor Freight electric impact wrench years ago and figured I'd try using that to remove the nut (my back up plan was to borrow some air tools). I also bought a set of adapters that would allow me to use the 1/2" drive wrench with the socket, which takes a 3/4" drive.
The impact wrench is 12V, so I connected it to the battery in my Miata.
That's a huge socket, huh? The impact wrench worked surprisingly well. The nut was off within 2 minutes.
That's a huge socket, huh? The impact wrench worked surprisingly well. The nut was off within 2 minutes.
Here's the flywheel:
And here's the engine with the flywheel removed:
Now, the folks at Revolt can come over and take the remaining measurements needed to design the adapter plate.
Motor is Here
Monday, February 23, 2009 by EV Hacker
My friend, Umar, and I just picked up my motor from the freight dock. It's sitting in my living room for now, but having a major part of the conversion here means it's one step closer to completion.
Here's another view to give some idea of its size:
It's a bit over 15" in length (not counting the shaft), around 9.5" in diameter, and about 150 lbs.
ยต-update: Motor
Monday, February 16, 2009 by EV Hacker
I just placed a winning bid on a 9" Advanced DC motor!
Get into the Groove
Sunday, November 30, 2008 by EV Hacker
Inertia. It can be your compadre or it can be a mofo.
There's a certain amount of momentum needed to keep a project like this going. The frictional forces of an unusually busy (and odd) work schedule, wrenching on my other cars, limited availability of parts needed to move forward on the conversion, consulting projects, dealing with my rental property, etc. were all bringing progress to a halt.
Knowing the longer I wait, the harder it is to get started, I figured I should at least work on something. Even if it's not significant, it's a matter of keeping some momentum. The good news is since I'm not constraining myself to significant stuff, I might as well do fun stuff (the two are often mutually exclusive). And as Neanderthal-ish as I'm sure this sounds, power tools can be the source of tremendous amounts of fun.
In this case, it's a Craftsman 8 amp reciprocating saw (bought on sale for $59.99 at Sears).
Install the blade, plug it in, and in no time at all, the floor of the trunk was out.
Eventually, some sort of battery box will go back there. That's a problem for another day. Today it was all about having some fun.
I'd say: Mission accomplished.
But there's more!
Later in the afternoon, Chris and Aaron from Revolt Custom Electric Vehicles came by with their coordinate measuring machine to capture dimensions on my transmission. From these dimensions, a design will be created, from which a machine shop will build the adapter plate and hub. Also, since the design is now in Revolt's library, anyone else doing a conversion on an FD RX-7 will be able to get their own plate and hub through Revolt.
Normally, having the transmission removed from the car is preferred since there's more room to work and it's easier to ensure a stable base (and more accurate samples). Chris and Aaron were beyond accommodating and were willing to give it a shot with my transmission in the car. Overall, the measuring process went pretty smoothly. Although I mostly just sat back and watched, it was very cool to see a 3D model being created from the sampling of points and curves.
Due to not yet removing my flywheel from the engine, there is one remaining measurement pending, but Revolt has what they need to get started on the transmission plate and will come back once I'm ready.
Out: Engine
Monday, August 11, 2008 by EV Hacker
The engine is out! This was the final item removed during the stripping process.
An engine lift made it easy for me to remove the engine. Austin EV generously offered to lend me theirs, but in order for me to use it, I would have had to borrow an air compressor and vehicle large enough to transport it. I found a deal at Harbor Freight so figured it was worth the investment.
With some tips from the guys at rx7club.com, the engine was out in no time.
I was able to keep the AC system intact. This should make it easier to have working AC once I'm running on electric.
Out: Exhaust System and More
Sunday, August 3, 2008 by EV Hacker
The engine is almost ready to come out. Over the last two weeks, I've removed the catalytic converter, downpipe, oil coolers and lines, lots of hoses, starter, power steering pump and lines, brackets and other small parts. The other things that connect to the engine (wiring harnesses, vacuum lines, etc.) have also been disconnected. Once I disconnect the AC compressor from the block, I should be able to pull the engine out.
Here are the parts I've stripped out so far:
Isn't it amazing just how many components (besides the engine itself!) are needed just to run a gasoline-power vehicle? So many parts. So much complexity. I don't know what every part does, but each one must be there to serve some purpose. Which means, each one is a potential point of failure.
By comparison, an electric car is simple and easy to understand. I wonder what they have more in common with: A gasoline-power car or a Stomper?
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