There is another patch under the rear seat which covers a hole created by the old starting battery. I am feeling a little more at ease with the sheet metal welding now. I will have a few patches in the body to weld which are going to show.
Saturday, September 12, 2009
More Sheet Metal Repair
This is some repair on some easier areas. There are two patches over the old speaker holes. Also there is a panel behind the rear seat. The three patches together provide separation between the rear battery pack and the passenger compartment, something I feel is very important for safety.
There is another patch under the rear seat which covers a hole created by the old starting battery. I am feeling a little more at ease with the sheet metal welding now. I will have a few patches in the body to weld which are going to show.
There is another patch under the rear seat which covers a hole created by the old starting battery. I am feeling a little more at ease with the sheet metal welding now. I will have a few patches in the body to weld which are going to show.
Sheet Metal Repair
I have begun repairing some areas of rotten sheet metal. I am using 18ga. metal which has been a little tricky to bend to fit some of these holes. Lucky for me these areas won't show when the car is finished.
Tuesday, August 25, 2009
More Welding - Battery Racks
I am continuing on with welding and installing the front and rear battery racks. Progress has been slow this month but at least I can call it progress.
Wednesday, August 5, 2009
Body work has begun
I am so happy to see this phase underway. I have a friend - Rick - who studied bodywork at the local tech college. I figure he has 30+ hours to get the whole car looking like the passenger door. There is quite a bit of body filler on this car. So after it is all sanded out we will be doing more filler work. And after that some primer.
The good news is that there are only a few sheet metal patches to replace rusty metal - Probably on the front fenders.
There was some rusted out metal in the front wheel wells. There are some pics showing where I cut and ground out the rust. These should be easy to patch since they are on the underbody and won't show from the exterior of the car.
The good news is that there are only a few sheet metal patches to replace rusty metal - Probably on the front fenders.
There was some rusted out metal in the front wheel wells. There are some pics showing where I cut and ground out the rust. These should be easy to patch since they are on the underbody and won't show from the exterior of the car.
Monday, July 27, 2009
Weld, Weld, Grind, Sweat
Whew! This metal working sure works up a sweat.
I have finished the motor mount and now I am installing some racks to mount the motor controller and a component board. The component board will have the charger, fuses, an Anderson disconnect, and a junction box for the heater relay and fuses and other misc. connections.
I moved on to the rear battery rack. I decided to go with 5 of the 10 batteries in the back (front) of the trunk. This will leave some space for groceries and stuff in the trunk. I had originally wanted to get the batteries down below the engine hatch but the controller is such a beast and there just wasn't room.
So I compromise, the batteries are a little high up, but they sit exactly over the rear suspension/ axles/ tires. And there is already a nice flat floor there.
The clearance to wire up the batteries is very tight,so in a few months I will be ranting and raving about what a bitch it is. I am going to get some big rubber gloves for insulation when I install the batteries.
I have finished the motor mount and now I am installing some racks to mount the motor controller and a component board. The component board will have the charger, fuses, an Anderson disconnect, and a junction box for the heater relay and fuses and other misc. connections.
I moved on to the rear battery rack. I decided to go with 5 of the 10 batteries in the back (front) of the trunk. This will leave some space for groceries and stuff in the trunk. I had originally wanted to get the batteries down below the engine hatch but the controller is such a beast and there just wasn't room.
So I compromise, the batteries are a little high up, but they sit exactly over the rear suspension/ axles/ tires. And there is already a nice flat floor there.
The clearance to wire up the batteries is very tight,so in a few months I will be ranting and raving about what a bitch it is. I am going to get some big rubber gloves for insulation when I install the batteries.
Wednesday, July 22, 2009
Sunday, July 19, 2009
Motor is in...
At least temporarily. I need to make a motor support. I decided to start with the old motor mount. I removed the old motor support from the ICE and then made a plywood template and layed-out the location of the new motor. I bolted the template to the old motor support and cut out the circular shape with my cordless jigsaw. A little grinding cleaned up the high spots and it fit perfect.
Next I will get the welder set up and beef-up this bracket and provide mounting points to connect into the Warp9 Motor.
Next I will get the welder set up and beef-up this bracket and provide mounting points to connect into the Warp9 Motor.
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