seligtype3 1969 Volkswagen Type 3

Post up a thread for your EV. Progress pics, description and assorted alliteration
seligtype3
Groupie
Posts: 123
Joined: Sun, 21 Nov 2010, 00:20
Real Name: Jem Freeman
Location: Melbourne
Contact:

seligtype3 1969 Volkswagen Type 3

Post by seligtype3 » Wed, 02 Mar 2011, 03:33

EV2Go wrote: Is the drawing to scale?


Yep, unless I've stuffed something up it's all to scale.
Restoring and converting a 1969 VW Type 3 Variant.

seligtype3
Groupie
Posts: 123
Joined: Sun, 21 Nov 2010, 00:20
Real Name: Jem Freeman
Location: Melbourne
Contact:

seligtype3 1969 Volkswagen Type 3

Post by seligtype3 » Sun, 06 Mar 2011, 04:59

Image

Starting to form a concept for the engine bay subframe. Thinking mild steel because it's what I'm most familiar with working but this is already weighing 10kg which sounds heavy.
Restoring and converting a 1969 VW Type 3 Variant.

seligtype3
Groupie
Posts: 123
Joined: Sun, 21 Nov 2010, 00:20
Real Name: Jem Freeman
Location: Melbourne
Contact:

seligtype3 1969 Volkswagen Type 3

Post by seligtype3 » Sun, 06 Mar 2011, 05:09

Another topic I've been mulling over is data logging. It'd be great to have good data on distance traveled, speeds, trip times etc so I been looking into Arduino shields such as this one...

Image

Linked to an Arduino I should be able log GPS data as the car goes about its business. Have to learn how to code the thing tis all.

Has anyone else attempted logging they're onboard data? It'd be great to get battery levels in there as well, perhaps the BMS is capable of outputting the necessary numbers?

Restoring and converting a 1969 VW Type 3 Variant.

User avatar
EV2Go
Senior Member
Posts: 2059
Joined: Wed, 16 Jul 2008, 00:21
Real Name: Paul
Location: Brisbane 1963

seligtype3 1969 Volkswagen Type 3

Post by EV2Go » Sun, 06 Mar 2011, 06:32

seligtype3 wrote: Image


Any chance of sticking the batteries above the red and black lines, inside the cabin? It would give better heat sheilding and better air flow around the controller / motor.

seligtype3
Groupie
Posts: 123
Joined: Sun, 21 Nov 2010, 00:20
Real Name: Jem Freeman
Location: Melbourne
Contact:

seligtype3 1969 Volkswagen Type 3

Post by seligtype3 » Sun, 06 Mar 2011, 14:33

EV2Go wrote:Any chance of sticking the batteries above the red and black lines, inside the cabin? It would give better heat sheilding and better air flow around the controller / motor.


Possible in theory but I'd lose the back seats and put the main pack in their place before intruding into the loadspace. Load comes before passengers on my list of considerations.
Restoring and converting a 1969 VW Type 3 Variant.

User avatar
EV2Go
Senior Member
Posts: 2059
Joined: Wed, 16 Jul 2008, 00:21
Real Name: Paul
Location: Brisbane 1963

seligtype3 1969 Volkswagen Type 3

Post by EV2Go » Sun, 06 Mar 2011, 17:25

Fair enough.

User avatar
gholm
Groupie
Posts: 115
Joined: Fri, 27 Aug 2010, 04:48
Real Name: James Neale
Location: Coogee
Contact:

seligtype3 1969 Volkswagen Type 3

Post by gholm » Sun, 06 Mar 2011, 17:26

re the GPS logger with Arduino....
Yes, this is something I'm scoping out and I've found a few different ways to approach this. Either Arduino or Basic Stamp seem to be the best route for beginner like myself.

I'm planning on using either a Uno or Stamp to make a Speedo/Tacho and Odometer using the built-in RPM sensor on my Kostov.

Both technologies have HUGE user forums, and plenty of online and physical literature to supplement the learning.

Plan of action. Get the tacho working... perhaps then a simple calc update to show speed ... later on, add a logging flash card for Odo and then further luxuries like GPS, battery temps, etc.

It is a reasonably steep learning curve, but will definitely result in a useful tool.

Keep us posted on your progress.

Some interesting links to various Arduino projects that are related.
http://tinyurl.com/6xelpe4 - the Jeeputer, homebuilt car computer using Arduino
http://ecomodder.com/wiki/index.php/MPGuino - Opensource fuel gauge

[edit for clarity and additional links]
Last edited by gholm on Sun, 06 Mar 2011, 06:48, edited 1 time in total.

User avatar
Speedily
Groupie
Posts: 123
Joined: Mon, 22 Dec 2008, 15:26
Real Name: Anthony
Location: Sydney
Contact:

seligtype3 1969 Volkswagen Type 3

Post by Speedily » Tue, 08 Mar 2011, 16:22

there's more power with twins :)
http://rebirthauto.com/ra-vwsa-twin.aspx

User avatar
EV2Go
Senior Member
Posts: 2059
Joined: Wed, 16 Jul 2008, 00:21
Real Name: Paul
Location: Brisbane 1963

seligtype3 1969 Volkswagen Type 3

Post by EV2Go » Tue, 08 Mar 2011, 19:26

Speedily wrote: there's more power with twins :)
http://rebirthauto.com/ra-vwsa-twin.aspx


SWEET! Image now if we just up the voltage and give it another go...

seligtype3
Groupie
Posts: 123
Joined: Sun, 21 Nov 2010, 00:20
Real Name: Jem Freeman
Location: Melbourne
Contact:

seligtype3 1969 Volkswagen Type 3

Post by seligtype3 » Wed, 09 Mar 2011, 23:15

Speedily wrote: there's more power with twins :)
http://rebirthauto.com/ra-vwsa-twin.aspx


such a speedy beetle, so good!

but i think the one kostov will suit my nanna-style-driving just fine.
Restoring and converting a 1969 VW Type 3 Variant.

seligtype3
Groupie
Posts: 123
Joined: Sun, 21 Nov 2010, 00:20
Real Name: Jem Freeman
Location: Melbourne
Contact:

seligtype3 1969 Volkswagen Type 3

Post by seligtype3 » Tue, 15 Mar 2011, 03:34

Been getting my cad on - engineer is happy with my weight distribution layouts so time to get some batteries on order and get the design stage rolling.

Image

Subframe bolts to the original rubber engine mounts, spec'd up in 3mm mild steel so weight is sitting at a whisker under 10kg for the frame only. Not too bad I suppose. The front frame will be much simpler as it will only be holding cells. Still need to add the mounts for the Soliton in this drawing...
Restoring and converting a 1969 VW Type 3 Variant.

seligtype3
Groupie
Posts: 123
Joined: Sun, 21 Nov 2010, 00:20
Real Name: Jem Freeman
Location: Melbourne
Contact:

seligtype3 1969 Volkswagen Type 3

Post by seligtype3 » Wed, 16 Mar 2011, 04:27

Image

Looking at the front pack - there's a flimsy bit of pressed metal at the front of the area where the fuel tank once was that would need chopping to accommodate the extra two cells at the front of the pack. Have to run that past engineer man I suppose. Four convenient M8 fuel tank bolts are nicely located to mount this subframe into place.

Question for the knowledgeable ones - The lithium cells like to be compressed yes, so is compressing them vertically like this going to achieve anything or should they be squashed in from the sides as well. Would prefer not to add more material but if the cells need it then I will!
Last edited by seligtype3 on Tue, 15 Mar 2011, 17:32, edited 1 time in total.
Restoring and converting a 1969 VW Type 3 Variant.

EClubman
Groupie
Posts: 64
Joined: Mon, 07 Dec 2009, 11:43
Real Name: Mark

seligtype3 1969 Volkswagen Type 3

Post by EClubman » Wed, 16 Mar 2011, 13:18

Lithium prismatic cells definitely have to be compressed on their largest flat sides.
I used 3mm flat aluminium plate and found that it bowed with the pressure, so use something thicker or perhaps ribbed (for the battery's pleasure - sorry :-)
Swollen cells have short lives.

Mark

seligtype3
Groupie
Posts: 123
Joined: Sun, 21 Nov 2010, 00:20
Real Name: Jem Freeman
Location: Melbourne
Contact:

seligtype3 1969 Volkswagen Type 3

Post by seligtype3 » Thu, 17 Mar 2011, 04:13

EClubman wrote: ...for the battery's pleasure


Thanks Mark, good to know. I'll rethink some details in the battery mounting department.
Restoring and converting a 1969 VW Type 3 Variant.

User avatar
Speedily
Groupie
Posts: 123
Joined: Mon, 22 Dec 2008, 15:26
Real Name: Anthony
Location: Sydney
Contact:

seligtype3 1969 Volkswagen Type 3

Post by Speedily » Thu, 17 Mar 2011, 10:45

most of the battery makers have these plates ready made and are cheep when you order the pac from them

User avatar
Speedily
Groupie
Posts: 123
Joined: Mon, 22 Dec 2008, 15:26
Real Name: Anthony
Location: Sydney
Contact:

seligtype3 1969 Volkswagen Type 3

Post by Speedily » Thu, 17 Mar 2011, 10:49

Is the frame bolted to the back of the motor aswell ?

User avatar
EV2Go
Senior Member
Posts: 2059
Joined: Wed, 16 Jul 2008, 00:21
Real Name: Paul
Location: Brisbane 1963

seligtype3 1969 Volkswagen Type 3

Post by EV2Go » Thu, 17 Mar 2011, 15:33

No rear bolt holes but I assumed they were just missing... Just looking at the cradle, the motor would need to be in place before the battery box section could be fitted to the cradle.

If the battery box was welded in there would be no way to fit the motor.

seligtype3
Groupie
Posts: 123
Joined: Sun, 21 Nov 2010, 00:20
Real Name: Jem Freeman
Location: Melbourne
Contact:

seligtype3 1969 Volkswagen Type 3

Post by seligtype3 » Fri, 18 Mar 2011, 03:34

ah yes the missing bolt pattern... will wait until I have the Kostov in front of me to suss out the back. and yes, good point EV2Go on the impossible assembly issue! maybe a slotted feature in the end plates to allow the shafts entry, then they get bolted in.
Restoring and converting a 1969 VW Type 3 Variant.

User avatar
EV2Go
Senior Member
Posts: 2059
Joined: Wed, 16 Jul 2008, 00:21
Real Name: Paul
Location: Brisbane 1963

seligtype3 1969 Volkswagen Type 3

Post by EV2Go » Fri, 18 Mar 2011, 04:39

I haven't seen the new Kostovs in real life yet but I would hazzard a guess and say they might be slightly easier to mount at the back than mine.

T1 Terry
Senior Member
Posts: 977
Joined: Thu, 30 Sep 2010, 20:11
Real Name: Terry Covill
Location: Mannum SA

seligtype3 1969 Volkswagen Type 3

Post by T1 Terry » Fri, 18 Mar 2011, 15:24

If the rear section of the frame around the motor was a removable section from the main frame the motor could be fitted and removed without removing the whole assembly.

T1 Terry
Green but want to learn

User avatar
Johny
Senior Member
Posts: 3729
Joined: Mon, 23 Jun 2008, 16:26
Real Name: John Wright
Location: Melbourne
Contact:

seligtype3 1969 Volkswagen Type 3

Post by Johny » Fri, 18 Mar 2011, 15:44

T1 Terry wrote: If the rear section of the frame around the motor was a removable section from the main frame the motor could be fitted and removed without removing the whole assembly.
T1 Terry
Yes. Bolt the larger sections together. So the front and rear motor mounting frames would be bolted to the battery frames.
Preferably the motor parts of the frame would be bolted to the mounting system so the batteries can stay in place if the motor needs to be removed.
I probably gave excessive consideration to maintenance in terms of being able to remove stuff without having to take everything out. Every one of our EV conversions is after all - a prototype.

BTW Jem. My motor and front battery frame weighed in at 14kg.
Your 10kg sounds pretty good.
Last edited by Johny on Fri, 18 Mar 2011, 05:05, edited 1 time in total.

User avatar
Speedily
Groupie
Posts: 123
Joined: Mon, 22 Dec 2008, 15:26
Real Name: Anthony
Location: Sydney
Contact:

seligtype3 1969 Volkswagen Type 3

Post by Speedily » Fri, 18 Mar 2011, 15:57

why even have the top part as is not needed :)

seligtype3
Groupie
Posts: 123
Joined: Sun, 21 Nov 2010, 00:20
Real Name: Jem Freeman
Location: Melbourne
Contact:

seligtype3 1969 Volkswagen Type 3

Post by seligtype3 » Fri, 18 Mar 2011, 19:58

all good points! thanks folks. thinking ahead for maintenance is an excellent point that has been escaping me. was only really thinking about assembly. cool, so motor can be bolted to the end plates then the end plates can be added into the assembly. will make the whole load easier to get in and out!
Restoring and converting a 1969 VW Type 3 Variant.

seligtype3
Groupie
Posts: 123
Joined: Sun, 21 Nov 2010, 00:20
Real Name: Jem Freeman
Location: Melbourne
Contact:

seligtype3 1969 Volkswagen Type 3

Post by seligtype3 » Fri, 18 Mar 2011, 20:04

Johny wrote:BTW Jem. My motor and front battery frame weighed in at 14kg.
Your 10kg sounds pretty good.


Ah good to know. I made a folded 3mm aluminium box as comparison as it came up much heavier. So 'real' steal will be my preference for now.
Restoring and converting a 1969 VW Type 3 Variant.

seligtype3
Groupie
Posts: 123
Joined: Sun, 21 Nov 2010, 00:20
Real Name: Jem Freeman
Location: Melbourne
Contact:

seligtype3 1969 Volkswagen Type 3

Post by seligtype3 » Fri, 18 Mar 2011, 20:10

POWDER COATING

So just out of interest I spoke to my powder coater about blasting and putting my whole moncoque chassis through their oven. Surprisingly they said, sure can do, and the initial quote has come in better than expected. Will suss out some more details next week but sounds like an appealing option... Make her look like one of these...

Image
Restoring and converting a 1969 VW Type 3 Variant.

Post Reply