Sunday, December 16, 2012

Drip, Drop, Drip - Open Primer Needs a Cover!

With the cooling weather - I have been attempting to get the Priming work finished and get the parts of the car I had been working on - painted.

The Roof was the start of this direction - and there were still some dimples and ripples in that - but I have managed to sand and fill with primer and get another coat of white paint up on the roof to seal it in, so hopefully that will hold over the Winter!

The Roof had been painted already - but in trying to sand and fill the remaining dimples - I felt since I had sanded through a few spots to the primer - I might as well give it a full coverage fresh coat of the Grey Primer - and then re-finish it with White Paint! I managed to get down a rough coat of White, but will likely have to sand it back again in spring!

The Hood - on the other hand - seems to have gotten behind the weather curve, and my available time - and still needs a few more priming and sanding cycles to smooth out some dimples and ripples, particularly at the forward edge.

I am trying to get at least as much done before snow comes, but the rain is no help too! Same with the freezing temps and working outside in the open just kills the deal!

I have been Mostly Wet Sanding with 240 Grit Wet or Dry paper, and moving to 320 Grit - Wet Sanding was already happening on the White Roof, before I re-Shot the Grey Primer!

Once I can clean up the dimples and ripples - I will start moving up from 240 to 320 - and on to 400, 600, and 800, If I have the patience for it, between paint layers.

I might top out at a medium level until I can get some of the other body parts taken car of first! Things like the Fenders and quarter panels and Doors, at least!

There is also the matter of the continuing under body - deep rust and metal mice chewing away at the car! After all - it is a 1989 Pontiac Firefly under the Electricfly project!

Friday, August 10, 2012

Put a Lid On it! (Battery Boxes Get Covered!)

Not yet finished - but on it's way - finally! After having the Battery Box Covers made up for the rear Battery Boxes (long ago!) - I have finally got started on getting them fitted!

The single battery box - required the total removal of the battery to proceed, so I had decided to take them all out - and have them tested, and cycled and tested again - to see what they would deliver for rated energy! One of our exhibitors for EV Fest 2012 has a 4-Battery cycle and test rig, so he has them at the moment.

Since I had the batteries out - I started work on getting the cover installed for the single.

There was a flat strap around the edge - but not wide enough to hold the clamp down bracket - so I cut two pieces of 1/16" x 1" flat aluminum bar about 1.25" long, and secured them in place using 'Mighty Putty' Epoxy that I had, clamped them in place, and let them cure for a day.

Then I used special Double Sided Sticky sheets, to temporarily hold the clips in place, aligning them by putting the lid on and clipping them to the closed position. After Carefully unlocking the lid, I clamped the clips in place one by one, and drilled first one hole, then bolted it and checked the cover fit - tweaking it for any alignment needs, before clamping the clip again to drill and bolt the second hole. I Did the same on both sides, then finished to tighten down the bolts.

With the single Battery Box Cover in Place - I began to deal with the issues of the main Rear Battery Box Cover and it's fit.

First - were the aft most flat edges, being at 90 degrees - they were scraping the plastic trim that was not in place when they were welded up, so I had to do some trimming and fitting - for a few fit cycles to get that right.

Then - was the issue of wire bundle clearance under the rear corners, and after hack-sawing, and grinding a few times, - I came up with cutting a much larger clearance, so I cut away more material, and used the 1" rotary File to Grind away and radius the corners for a safer, smoother clearance with fewer sharp edges.

Next - was the issue of the 4 original holes - that we first drilled in the side flanges along it's center-line, but they were along the edges of a dip, and on the side - where the hole - while vertical - would end up tipped inward on all 4 holes if I simply inserted the desired screw-nuts. So I decided to again get out the Mighty Putty - and simply use it to fill and level the space. First - I took my Wire Wheel (Actually - a synthetic replacement) in a 3" Dia. and using the Drill - I cleared away - Paint, Rust inhibitor, and underlying Rust, before using a small steam cleaner to cleanse the area of fine particles, dust, and crud. Drying that first with paper towel, and then my heat gun, I was then ready for the Might Putty!

After cutting 4 pieces of thin coat-hanger sized rod to insert in the 4 holes, I mixed the putty - one hole at a time, and then forced it into the depressed area an around the rod, wiggling the rod to keep the hole clear, and patting it down to make a basic Level condition. It was not until I got to the last hole - that I thought to use a stiff plastic Spreader - to pat it down in a true flat surface! (The others were already too hard to mold any more by that point.)

After letting them cure for about 10 more minutes - I got out the Heat Gun again - and gave them a bit of acceleration. Then - I started to mask off the area around each sides two holes, and once that was done - I shot them again with rust Primer, for a few coats and let them cure for another day!

After Removing the masking and paper, I chose the size of Screw Nuts (10-24), and drilled the insert hole for them. Unfortunately - I only had handy 1/4" drill bits, and needed a bit larger. So - I took a Round file and began to work the holes to make them larger - until the screw nut just slipped in.

Unfortunately - I made one hole a touch too large, and so - after installing the screw nuts, and fitting the cover, and testing the fit with  bolts - the loose one pulled up. I will have to get a fresh one - and start again - but likely use a bit of fresh Mighty Putty with the install - or some other Epoxy - and let it cure before testing the tightening again!

Here are the two covers in place - with the smaller Single Batter Box Cover forward, and the large - 4-Battery Cover Aft:

Once that test fit is in place - the next step is to secure spacers for the flanges - using 1/2" thick Pink Builders Extruded Foam, adhesives, and Epoxies, etc. to set up a hard and level offset to raise the cover flanges up so as to clear the wiring that enters the battery box from the back face.

Wednesday, August 1, 2012

A Couple Free EV Fest 2012 Tickets for my Followers!

Coming to EV Fest 2012? Want in for Free? Just start By Clicking Here to get your 100% Discounted Advance Guest Tickets  - On Me!

Oh - and I am getting some time to work on Electricfly - Have the Single Battery Box Cover Clips installed so I can Clip down and lock the Battery under a cover, as well as a Hold Down - keeping it away from prying fingers when I take it to shows - Like EV Fest 2012 Electric Vehicle Show!

Looking for More EV Fest 2012 Information - Come over to the site and See the Exhibitors, under the 'About' Menu item, or Get Tickets information under 'Tickets, etc. - go to EV Fest 2012 Electric Vehicle Show Website!

Saturday, May 12, 2012

EVCO EV Expo in Ottawa, Ontario - 1

Sitting in Brockville, on my way to the Electric Vehicle Council of Ottawa`s EV Expo! Have a stop to make' but should be there by lunch! I will see if I can get some good pics and info posted later.

Monday, March 12, 2012

Gas Pedal? What Gas Pedal? How about - How much Gas was saved?

Some people driving electric cars seem to get stuck on last century terminology - Gas Pedal! How about Accelerator Pedal? Or just Go pedal, the one beside the Stop pedal (The Brake Pedal)! Maybe we should color them Green for Go Pedals, and Red for Stop Pedals!

Also - some reports are coming in and say that Electric Car Sales have not exploded, so they must be dead!! Well - let's just compare - how many sales of other premium cars were there last year? (No - I don't have the answer - that's why it is a question!) Or - how about this - how many Extra Gallons (or Litres) of Gasoline were available for other drivers last year because of the electric Cars that did get sold?

Since an Electric car uses no Gasoline - ALL of the Gas it would have used if it were Gas Powered - is available for other cars! No Matter how many miles per gallon it would have gotten in a gas powered equivalent!

The Possibilities for an electric car to be fueled, if you will, by electrons moved by the sun, in your own properties space, via a Solar Photo-Voltaic panel (Solar PV, or Solar Electric), while likely a bit on the expensive side, generally have issues with creation, but cause so very little pollution with use as to be nearly non-existent, EV + PV = The True Green Solution!

Search EV + PV and you will find a number of sites on this subject! Like Jeff Chan's very descriptive pdf report by Sherry Boschert.

Beyond that - in My mind - Solar Power Production, in Work Parking Lots, that Feed the Grid, and as electric vehicles grow in numbers - charge them up - would do a lot to clean up local air conditions in Cities, and reduce the concentration of pollutants along road sides and in work site parking lots!

For those who want, but can't afford, an Electric Car, and want more than a 15 - 20 mph electric scooter, there are high powered electric scooters and Electric Motorcycles coming out now for 25% of the cost of an Electric Car, with - in some cases - even more range!

In all - the day of the Gas Pedal - is something your Grand Children might not even know about! Maybe even your children, if you are still young yet! Between Electric Vehicles, and Self-Drive Technology - either one or both of these items are likely to remove the terminology of the 'Gas' pedal from our vocabulary!

Enjoy your Gas Pedal While you can!

Wednesday, March 7, 2012

Discovery about the Trojan SCS150 Flooded Lead Acid Battery - the 1 Hr Rating!!!

I Finally found out the Actual 1 hour rating of the Trojan 100 Ah SCS150 12V Battery! It looks like Trojan Document MFSCS-6/01 and compares the Trojan SCS Series - the 150, the 200, and the 225: Group 24, 27, and 31 - Respectively, showing their performance from 1 - 25 hours!

It is rated at just 30 Amps for 1 hour! That is just 30 Amp Hours when compared to the 1 hour test ratings of the Lithium Iron Phosphate Cells! So the Blog Post - comparing the ThunderSky 40 Ah cells to the Trojan 100 Ah Cells - is not realy so bad after all - with 33% More Energy to 100% DOD versus the Lead Acid, and - interesting enough - the PRC-1255A Batteries I just tried in the car, as a new set - had a spec rating at 1 hour of 32.1 Ah - even more than the Trojan 100 Ah Batteries, and they are rated at just 55 Ah! Plus - the Weights:

Trojan SCS150 Group 24 100Ah rating at 20 hours (30 Ah at 1 Hr) Battery Weights 50 Lbs each x 8 = 400 Lbs.

Power Battery PRC-1255S, with a 55 Ah Rating at 20 Hours (32.1 Ah at 1 Hr), Weighs just 44 lbs per battery x 8 = 48 lbs less at 352 Lbs!

The Thundersky 40 Ah Lithium Iron Phosphate puts out a full energy of 40 Ah to 100% DOD at 1 Hr, and weighs just a maximum of 1.6 Kg per cell x 32 cells = 51.2 Kg = 112.64 Lbs!! just 2.25 Trojan Batteries weight by comparison!

Tuesday, February 7, 2012

SLA Power Battery PRC-1255S update

Had some Friends come over to help me try to get Electricfly Ready for EV fest 2011, almost made it - but had a charger problem - one of the custom chargers setups for the front 3 traction batteries, plus the accessory battery - failed on Traction Battery #2! The new Batteries I was putting in to try out - are smaller - only rated at 55Ah - but not much lighter at 44 lbs vs. the 100 Ah Trojans at 50 lbs! I heard some good things about them and some bad, plus these are used 24 - 30 months working in an Industrial UPS system - Emergency Lighting power, but I got them for Free, just check them and pick them up - so hard to complain, but when I tried to get a price on them new - the company was out of business!

Technically - they are rated at about the same capability as a ThunderSky 40 Ah Cell = 2 hours at 0.5C load = 40Ah for the TS, and 2 hours at 20.5 Amps for the Power Battery (just these are much heavier - 20 Kg vs ~6.4 Kg for the TS!)

For an interesting opening read on this - check out this question - What is the Cost of a Pound? pdf document!

In any case - I have also since found one installed in the back to not hold a charge well, so have to swap it with a spare I kept!

Friday, January 20, 2012

My Electricfly - Plans to exhibit at EV Fest 2012

EV Fest Electric Vehicle Show 2012
I'll be at EV Fest 2012!
See my Electricfly at Evergreen Brick Works!
550 Bayview Avenue, Toronto, Ontario, Canada
Join us in The Pavilions!
Sunday, September 9th!
Hours: 10AM - 5PM!

While I hope to have My Headway Lithium Pack Completed for EV Fest 2012, I might only have a small Pack installed just for initial Testing Applications, but either way - I am going to have it at EV Fest 2012!

If you have a Personal Electric Vehicle, and would like to Exhibit it at EV Fest 2012, now is the time to get your plans ready and get Ahead of the Curve! Check out the website for more information!