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Monday, September 21, 2009

Being a Eco Pro Recycler


Here are a few strict guide lines that I follow to ensure a happy and productive partnership of parts. Remember most companies have to pay to get rid of some surplus.


1.If you don't ask you will not receive, but don't steal!
2.Tell them what you are really doing, don't lie, they may be even more happy to help you if they really dig your project.
3.If they say no because they need it, don't steal, ask if they may know where you may get one.
4.Offer to pick up the part(s) at their convenience night or day and if you are qualified, offer to remove the parts with your own tools and ask what tools you will need when and if you need to come back (mechanics are very sensitive of their tools).
5.If they scrap parts for scrap metal weight or trade them in for a core charge, offer to pay them in cash for that.
6.If you have special skills that they may use, you can also barter your services for their parts.
7.Don't sell the parts for any reason, if the donor company finds out they will cut you off.
8.Clean up after yourself.
9.Don't be a pain in the rump, ask when to call again or if they want to call you.
10.Don't hog things' spread the wealth give things away too, ask if they need it back if you can't use it after all.
11.Don't sort or separate there take it all home, don't be a pest and most important - clean up after yourself.
12.Do be very thankful.
13.Do be educational.
14.Do be humble.
15.Do bring 1 or 2 pictures of you project so they may see your vision and also become inspired.
16.Have fun and wear safety shoes and always have a first aid kits.

Thursday, September 17, 2009

Spraying On Your Trunks

Asphalt Undercoating was sprayed to the entire trunk and wheelwell area and at $7 and $10 a pop at Canadian Tire www.canadiantire.ca really cleans things up.







And They Say I Don't Have A Spline


So trying to find the spline that would fit the Crown TSP drive motor donated four weeks ago came up short, but the same fantastic corporation was replacing two drive gear systems in a lift truck and donated them for our project. Each drive system weighs about 200 lbs.

Spline Removal Purpose Video 1
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Spline Removal Purpose Video 2
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Spline Removal Tool Video
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Wednesday, September 16, 2009

Having A Wheel Well Good Time

Time to repair all the rust outs, this will be my first time working with Bondo fibreglass with hair. As does everyone else in the world embarking on a new project, I have now completed 93 straight hours of YouTube tutorials and now feel qualified and brave enough to crack the first can of Bondo, I received 5 cans of Bondo free so when I make a few mistakes I won't cry to loudly. I have long ago and lots of times used Bondo Body Filler alone, let the fun begin.

Battery shelf rust out.

Right and Left wheel well rusted right through.

Friday, September 11, 2009

Things That Were Never Meant To Go Together

Here is a close up of the two main components but three things that were never meant to go together.


  1. On the right - 1984 Pontiac Fiero standard transmission.


  2. On the left - 72 Volt 7.6 Kilo-Watt Crown TSP drive motor.


  3. Me 39 year old dreamer that can't let anything go to waste.


The 2 drive motor power a 14,000 lb or 7 ton lift truck.




Thursday, September 3, 2009

Wire Wire In The Wall

Now comes the time to find a shorted ground wire in the frame tunneling, body frame or light socket that is for the tail, licence plate and side marker lights. The stop, turn, hazzard and brake lights work.


  1. 1st. You need this.


2ND. You will need this.



3rd. You may need 13 of these.



Mounting Battery Rails

Mounting the battery bank rails made out of used aluminum transport trailer roof rails. that were donated to the project. Remember people ask if you can have it, everything for the project was donated.









Son riveting battery rails in place. How many kids are building Electric Cars these days, I know of only one. Despite the sad look on his face he is actually having fun.




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Load testing the battery grouping with a little jump.







Video jumping.



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Battery configuration, trying to maximize space and balance the weight of all the pack. Each pack weighs 20 lbs, so just in the front there is 360 lbs.



After the battery placement has been finalized then we will add both fibreglass and rigid insulation to enclose the boxes to maintain the heat for the winter time. We will add vents and controls for the summer time.

These rails were cut down to bridge the gap across the front void where the spare tire (center) and the radiator (right) use to be.

These rails were also riveted in place by our son, he also calculated the correct Ah capacity that the car would need to travel 150 km.