Preparing for the Paint and Building the Box for the Batteries

I am not updating so often anymore because we are working so much on the car and much of the work now is kinda boring. But as soon we get it back from the paint job I will start posting regularly again.

I have worked on preparing the car for the paint and Simon started to build the battery box.
We will paint the inside our self and much of the sides will be covered with panels.     

Rear left side before the paint. 

Rear right side after a little paint.

We also tested the motor and transmission assembly to see if there was any weird noise or vibration. Now it is ready to be put in the car.

Controller, motor, transmission and cables.

 Simon started to work on the battery box that is going to be under on of the seats.

Sturdy metal frame to hold over 300 kg of batteries

Now I will end this week with doing some paperwork and getting some rest.

Yay, the Bodywork is Done

 This week Simon welded the last bodywork on to the car.

Custom made part.

Left side is done

 Now we only have one part left to fix. The fuel tank inlet.

Abra

Kadabra

Alakazam

Where did it go? 

 And I installed the vacuum pump.

Now i only need the last parts for the brakes so that we can test if it works. 

 We did not get any documentation on the motor/controller system. So I opened up the controller so that I can figure out how we are going to connect it to the system.

Almost done with the bodywork

This week Simon continued with the rear right corner. 

Checking if it fits.

Can you spot the welding?

Also last week Simon upgraded the workshops sound system.

BOOM BOOM! 

 Then he started to fix on the corner.

Old vs new 

After the welding we tested that the signal light box still fitted.

We only have one bodypart left to fix. So with a little luck we can start work on more fun stuff.

Surprise! More Bodywork

This week Simon has started to replace the bigger side plates.

Rear left

The new toy we got.

It bends the metal so the welding is super easy.

The new plate in place.

 Then he started to work with the rear right plates.

The new parts.

The battery tray.

Cutting away rusted parts.

Preparing for the new plate.

 I have started to install the new brake lines.

The front part of the brake system.

The rear part of the brake system.

I still have 2 pipes left to install, but i need to wait until we have the parts we are missing for the right side brakes.

We also have talked to some guys about the adapter plate between motor and the transmission. They gave us valuable information about how we could solve our problem.

While we were talking we noticed a weird thing on the motor. The company that have made this motor fucked up and drilled wrong. They somehow drilled the hole for the flange and the hole for the hoisting ring at the same place. So they had to drill a new hole for the hoisting ring a little to the side.

Prime example of a fuck up.

You can see how only half of the thread is left.

Much school work and a little car work

So first some pictures of things that we finished last week but i forgot to take a picture of.

Good as new

Left door after its makeover

I had started to renovate the gear rod and now it is fixed.

Old vs new

I also took out the transmission so that we could get more room when working on the adapter plate.

I think it likes to be tied down.

Simon got out the brake pistons from one of the calipers. But on the other one the piston broke and we started to look after new ones. Alternative we buy a new caliper.

Left front brake is done. Now i just need to fix the brake pipe system.

Simon started to work on the right side door. Not as much damage as the left side so it soon was in working condition.
Then he moved along the right side and fixed various rust damages and old repairs.

Next week we have more time for the car and we hope we will get much progress done.

/Oskar

Santa is early this year

First thing first. This is how the engine room looked after Simon´s hard work and some paint.

We are going to do the final paint after the motor holder is in place.

Okay so we had already got the motor and controller but they forgot to send us the switches and control cables, and we have been waiting forever for them to send the rest of the parts.
When finally we got it, guess what, they still messed up and did not send all the parts we ordered.

The cooling pump, 3 switches and a battery gauge.

Cable that goes from the controller to all the switches. 

The motor that got delivered 3 months ago.

The controller that we got at the same time as the motor.

We also got a crazy big vacuum pump because PAF wanted to pay a little more when it comes to the brake system. 

The vacuum pump that also got delivered with the motor and controller.

 We also got our repair parts for the car.

Big package for big boys.

One of the many boxes we got.

Started to check if everything got delivered.

Simon started with switching out metal panels.

This is such a simple metal panel that we could have made it ourself but it did not cost much so what the hell.

Just doing some measurements.

Now Simon had taken away all the rusted metal and painted the inside.

I started to check on the breaking system and decided to start on the left front disc brake.
We had decided to keep the caliper and switch out almost everything else.

Let the transformation begin.

I did not get long in the process before i got a problem. The brake pistons were crazy stuck and we did not have the proper tools for taking it apart. So i have to go and borrow the right tools next week.

While i was at the brake i changed the shock absorber and painted the brake plate.

While i waited to fix the front brakes I started on the rear brakes.
And once more i got stopped in my tracks, we had forgot to order the brakeshoe self adjusting screws for the brakes.
So i started to work on the gear shift/transmission but i have no pictures of that yet.

Old to the left and new to the right.

At this point Simon was done with the panel at the back and had moved to the driver side floor step. 

I forgot to take a picture of how it looked before he started. But if i say RUST you maybe get the picture.

After a lot of measuring, 3 metal plates a fair amount of welding and a little paint this is how nice it got.

Simon got a whole 10 minutes of rest before he started with the next thing.

Next up was the door. It had much rust along the bottom side and it was basically the paint that hold it together.

A quick check if it was the right door we ordered.

All the rust have been cut away and we can see the entrails of the door. 

Only a little welding left and it can be mounted back on the car.

So this week we got much work on the car because we were free from school and we got most of our stuff.

/Oskar