Bondo and Fibreglass

Now for the part of the job I hate.

The perfectionist in me is very good at Bondo and fibreglass (I re-built a boat a few years ago) but man is it a terrible job.

The bumpers and cracked in a few spots and need to be strengthened and there are the inevitable dents and dings.  The Vitrara is in great shape otherwise and only has about 6 dings that need to be fixed… but it’s still a bit of work.  The goal is to get the paint and interior done by the end of Sept so that all is left is installation of batteries and electric parts to get done by the end of December.  I’ve been told this is the easy part!

To add insult to this injury, I’m also removing tire from the back door as I don’t need the weight or the spare.  This means that I need to take the “bump” out of the rear bumper and make it look like a single piece.  That’s the next thing to tackle!  Fun :-S

Wrecker Visit

Well I had a day off work so off to the wrecker I went!

Picked up a bunch of parts for my truck (which took a total of 2 weekends to install), and I ended up with seats for the Vitara.  The seats in that car were a mess.  300+ km on them and not well taken care of.  They needed to go.  I was looking for (and found) a set of Jeep Grand Cherokee seats from a 1998 Jeep.  Dark gray to match and full power and heated seats!  Great find!

Also found head rests to replace as they didn’t come with the Vitara.  Also picked up a battery so that I can move things like windows on the Vitara as I’m working on it.  Very difficult otherwise!

***I’m learning as I write this I need more pictures!***

Batteries… the endless question

So now that the Vitara is in the “work” bay I’ve had the opportunity to take some measurements and start the planning in my head.

Although a Leaf pack is very functional and easy to work with, they are very “hot” items right now.  A single wrecked leaf is going for anywhere between $3000 and $5000 USD on Autobidmaster.  That’s a bit more than I want to pay for a battery pack, not to mention I want 1.5 packs which involves buying 2 cars!  Yes I can sell parts and make some of the money back, but after doing that with the S10 I’m less than excited to do that again, let alone twice.

In terms of battery packs I’m looking for somewhere in the range of 30 KWh at 144 Volts.  I have all the parts for this and the 144 Volts will allow me to upgrade to an AC motor in the future if I so choose.  My search for batteries lead me to the Chevy Volt.  These packs are a little more volatile and difficult to work with than the Leaf cells, but they come in 48 Volt cells with included heater and cooling system.  Not a bad deal if you ask me!  I would need just under 2 of them (leaving me 1 48 volt pack left after) and they are $1,800 USD at a wrecker just across the border (less traveling for me).  These cells also come with wiring for a BMS system.  It’ll need to be a large and expensive BMS, but easy to connect.  Seems like a good plan so far…

***Problem… with the cooling system these packs are big, and take up a lot of space.  This means I can find room for 2/3 not problem, but I have more cells to find space for.  This is going to be a challenge***

Soon I’m going to need to get my hands on a pack to get exact measurements.  There is a really good thread on these cells here: http://www.diyelectriccar.com/forums/showthread.php/2012-chevy-volt-battery-93101.html  It’s a huge thread but there are a lot of details in there.

Onwards!

Dismantling of the S10 is complete!

Well a wedding stalled the process for a few months, but I now have all the parts out of the S10.  It was about 5 days of tracing wires, and trying to figure out why things were hooked up the way they were.  I still have questions, but the huge amount of pictures I took and notes on what wires go where have lead me to believe that one day I’ll be able to put the Vitara back together.

One thing that amazed me is how everything fits together.  When you’re used to working on Gas motors as I am the size of the electric motor is so small!  And it mounts up in such a simple manner!  All that space you save is taken up by batteries though so don’t get too excited!

I’ve noticed one thing about DIY’ers… they tend to cut corners.  I bet I will as well but when I opened up the electrical boxes there were wires EVERYWHERE!  I get that happens, but there needs to be some method to the madness.  No colour coding, not notes makes it very difficult.  Also, once a wire is outside the electrical box there was nothing covering them up.  In modern cars they all use convoluted tubing (or wire sleeves) so that it looks neat and tidy but also protects the wires.  I know I will go that route… the previous owner did not.

Once all the parts were out and I listed everything for sale, I actually sold a large part of the truck.  So much that I actually had to pay someone $100 to take the S10 away.  I know I should have taken a picture but I completely forgot.  Let’s put it this way, there were no doors, windows or axles on the truck!  Still some left over but made back close to $2000 on the cost of the S10 so that is a great accomplishment!

Now that the S10 is done I can move the Vitara into the working bay and get it all underway!  Next step is to get the outside of the Vitara prepped for paint and finish the interior.

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