It's Alive!

It has been a little hard to get motivated with snow on the ground in May.  It almost appeared like there would be summer a couple of weeks ago, but it was a ruse, it's been raining and feeling like October since.  Nonetheless, the young men want to drive this craft to school before graduation, which gives us one week!

The past couple months can be best described as wiring and troubleshooting.  Not much that was newsworthy anyway.  Most recently we turned the key, nothing.  Found the wire that was cut when the engine was removed, fixed, turned the key, lights came on!  But not the motor controller.  In combining several wiring diagrams (controller, motor, charger, project instructions), the main contactor relay was in a place that didn't allow the controller to have both positive and negative until after it was already on.  Paradox.  Fixed that, then the motor would turn at 40 rpm while drawing 100 amps.  Figured out the proper motor wiring connections and voila!  Here's what happened this morning:

Since then, we also were able to start charging for the first time, although because of the same relay placement issue we need to move one connection to allow charging with the key off.  And the charger itself needs a way of being mounted in the trunk.  And a hundred other details... but I think we have a shot at the driving to school thing!

A mess, but we wanted access to the wires until it ran.

It's Here!

Our new family member arrived today.  We met the driver at the truck stop a few miles away so he didn't have to negotiate our little road with a 53' trailer. 

Many people have asked me "Are you going to drive it in the snow?" - OK, I don't get that.  I live in MN. If I don't drive it in the snow, then when DO I get to drive it?  Only the same few weeks that I want to drive my electric Miata.  So, I'd better drive the S in the snow.  And slop, and salt, etc.

So far, it's everything promised.  I was happy to see that although I cheeped out and didn't order the tech package, I did still get maps and a backup camera (just not high res).  And for the moment, it has full 3G connectivity so I can surf and check my email while driving (ok - I will try to avoid that temptation).

We made a trip into Minneapolis and back, 55 miles, tonight at 15 degrees F and used up 70 miles of "rated" range, so a cold weather reduction of 22%, more or less as expected.  The acceleration is not quite like the stomach churning Performance version we test drove, but still a silent thrill ride (5.6 sec 0-60).

About the only thing I can find to complain about so far is the shortage of cup holders (there are 2) and interior storage.  The center console has no covered storage, and the center arm rest is just an arm rest!?.  But the back end looks plenty big enough for my string bass (with one seat back down), and as you see in the video, the "frunk" is a comfortable place to kick back.

As for the Miata, hopefully she's not feeling jilted having to share the garage with this prima donna.  We have been plugging away a couple hours every weekend.  All the batteries are in and wired.  We have the high current cables all done and most components installed.  Lots of other wiring left to do.  And spring is coming in one month officially, but at least two from a convertible standpoint. 

Baby Steps

This whole project could be a little overwhelming.  But without any real time pressure, stringing together many little tasks makes it quite do-able and less daunting. Trouble is, you don't note any real blog-worthy milestone.

Jared and John making a battery pack for the nose.

Realizing then we're a bit behind in communication.  Since the last post, we've gotten the top and front battery racks in.  The latter was a conundrum because the mounting holes were seemingly in the wrong place.  Easy fix, but only after several emails and much hmmm'ing in order to determine that Mazda evidently moved something in the front sway bar mounting for 96-97.  So, it wasn't me.  Also now have cables from the front to the back and batteries in two of the 4 spots.  Each cell gets its own battery management system (BMS) circuit board and a strap to connect to its neighbor.  The challenge was to lay them out in a way to minimize the pieces of cable required, fit all the cells in the racks and hope that you can get to the connection spots once you've tipped the under-hood batteries on their side (required for the "fit all..." requirement).  14 in the trunk, 16 under the hood (8 on top and 8 in the nose).

Batteries on one side of the nose rack.  Top rack on left.

Along the way I determined that the charger I selected is too tall to fit under the hood.  Oops.  But it can go in the trunk just as well.  Very glad that was sorted out before pulling cables through the conduit, because it affects where the wires have to go.  Would have been an epic bummer to learn this when trying to close the hood for the first time.

14 in the trunk.  These will get covered with a clear plastic plate.

Other than mounting a few electrical components our mechanical work is about done.  Wiring will likely take a long time with a few more lost hairs.  Wiring diagrams provided with motor, controller, charger, BMS, conversion instructions create quite a puzzle.  And when we turn the key the first time....?  But that is many baby steps down the path.

In other news, I was quite surprised when notified that the Tesla would be ready for delivery between now and Feb 12!  Scrambling just a little to get a 220V 50A plug in the garage connected to the off peak meter.  Although it will charge from a 110 outlet, just slowly (and with a cost of about $.04/mile vs $.02). So, we won't be motoring in top down Miata style while waiting for the big EV, but still have our sights on a Miata deadline loosely defined as "spring".

Motor IN! Trunk Rack IN!

I think I could cut the time required for this conversion by about 2/3 if I did it again, simply because my head scratching time would (hopefully) be reusable.  I'm taking notes, I don't expect to actually remember. 

The adapter took more fussing and thinking than I expected, but we made a template, cut the outside with a sawzall, pinned it for alignment , marked and drilled holes and sanded the edges.  It's a good thing my good and sharing buddy Russ has lots of the right tools!

Sadie helping Jared install motor mounts

Jared, his friend Zach and I mounted the motor to the adapter, hoisted the 130 lb assembly in and bolted it together.  Well, actually they did the hoisting and I did the guiding.  We elected to do it "by hand" instead of taking the time to rent a hoist again.  With some straps and a 2x6 this went ok, but if we did it over, I think I'd put a couple hooks in the ceiling and use a come-along.

Motor IN!

Trunk Rack IN!

We received the batteries last Thursday.  Thanks to Mikey at EV Source for tracking down the truck for us and to our friend Brad for loaning the dock at his office which significantly reduced the shipping cost.  Each battery is about the size of a thick hardcover book and 12.5 lbs.  3.2V x 30 in series = 96V nominal (108 fully charged, 75 fully discharged).  All together 17.3 kwh rated.

Batteries

Starting to Put Things Together

We have quite a collection of parts now, and are at the point where we can start putting it together. Expecting the batteries to arrive tomorrow.

Today we dropped the sway bar to make room for the nose rack and did some other assorted cleanup.  Almost have the manual steering rack in place.  The transmission adapter is a little more DIY than I expected, and we need to trim it up quite a bit before making it fit, then need to locate the holes.  I'm going to match drill 2 pins from the outside to locate it, since that was part of the engine, and all the bolts are a loose clearance fit.

Sway bar dropped with black square tubing lowering block

Empty Compartment - Have refrained from cutting excess wires off just yet

Tesla Distraction

I've been a bit distracted by the Tesla Model S which I reserved last June (for the days you don't want to drive a 2 seat convertible).   We received a surprise "Invitation to Configure" email 2 weeks ago, which is a nice way of saying "Lock in and commit now or lose your 2012 pricing".  So Lauren, Joan and I took a little road trip to Chicago this weekend just to pick out colors:-)

 Joan evaluating the seat comfort.

Lauren picking out her 16th birthday present early.

I was delighted when the Product Specialist, Zarina,  invited us to take a test drive!   We had a Performance edition and got to do the same loop that we took in July, except we had time for 2 laps and much more time to explore the car.  Other than Lauren feeling a little woosy after testing the 4.4 second 0-60 spec,  it was great!  Additionally, Zarina was extremely helpful with questions about the car.  In particular it was good to learn much more about the display and controls.   She also had more information about Tesla's planned "Superchargers", across the country.  These give you a 1/2 charge in 30 minutes and will be placed along major routes.  Currently in California, the red dots are planned in 2 years and the dark dots are in the long term plan.

Other than that, we now have a motor and transmission adapter waiting in the garage.  Batteries, brackets, controller, charger, DC/DC Converter etc. are on the way.  The engine compartment is cleaned, but I didn't think you needed a video of that greasy project.  Manual steering rack is just waiting for the stubborn tie rods to come apart on the old one.  Vacation requests are submitted.  We shouldn't have any excuse for not making lots of progress over the holiday.

Insanity Reigns!

To remove the engine from a perfectly functional auto violates the sacred dictum: "If it ain't broke, don't fix it".  I've pulled engines quite a few times, but we always broke them first!.  My tool kit and skills have deteriorated a bit, but with a couple trips to Sears and little help from the instructions, it is done.  The basics haven't changed in the 30 or so years since last time, but there sure are a lot more wires and tubes in a '97 Mazda than a '72 Ford.    I'm glad I don't have to put this back in and expect it to work! 

It actually took Jared, John and I about 6 hours with prep and clean up, but I thought you might prefer the "Reader's Digest" version.

Engine and exhaust out.  Minus about 330 lbs.  Mounts and battery boxes are being made and powder coated.  I'll order the transmission adapter, motor and controller on Monday.  There's still some cleanup and prep to do, but we'll look forward to installing new stuff over the winter school break.