October 31, 2012

Brake parts arrived!

So, after long time thinking I have decided how to convert the brakes. In the front will go larger (280mm) disc brakes from a Golf IV. Since the A2 has built-in caliper holders, larger discs won't fit so I'll change the whole wheel bearing housing. I bought new rotors and pads and used calipers and wheel bearing housing. The wheel bearing housing also includes wheel bearings and hubs. I hope they will fit the A2 drive shafts!
In the rear go disc brakes also from a Golv IV with new rotors, calipers, pads, and splash guards. The caliper holders are the only thing missing now. They are ordered used from bildelsbasen.se. I will have to manufacture the adapters for the calipers also.
Now I really want to start converting brakes! However I need to get the car approved before I convert the brakes so that I can legally drive it for one more year. If I don't get it approved before dec 1:st it will become illegal to drive. And I can't get it approved after I changed the brakes. I have to wait until the whole is converted to electric to get the full approval.
So, I'll sit still and plan to start conversion the weekend after next.

October 21, 2012

Brakes (the stiff Swedish regulations for converting cars)

In Sweden, if you want to convert a car newer than 1993 you have to change, not only the motor, but also the whole brake system or the steering system. This means a lot more work. I don't want to convert an older car. I want a relatively modern and safe car if I'm going to bring my family in it every day.
So, I will change the motor, the transmission and the brakes. I'll start with the brakes. I don't want the whole project to fail in the end just because it's impossible to change to other brakes on this specific car.
In order to get your converted car approved in Sweden there is an organisation called SFRO, Svenska Fordonsbyggarnas Riksorganisation, Swedish national organisation for vehicle builders. They will pre-approve the car before the vehicle inspection approves it. According to a person I have been in contact with there, I need to change the brakes to something with "different performance".
The A2 has front disc brakes and rear drum brakes so "different performace" in this case means fitting larger discs in the front and probably discs instead of drums in the rear.
The holders for the front brake calipers are an integral part of the wheel bearing housing and it is not possible  to fit a larger rotor. The holders limit the diameter of the rotor. So, this means I have to change the whole wheel bearing housing. Check out this exploded view. Nr 11 is the wheel bearing housing. See the "hooks" to the left that won't allow a larger rotor.
I hope I can find a wheel bearing housing from a VW Golf or something that can house the larger rotors. The next rotor size is 280mm.
The rear brakes do not have any "ears" to bolt the calipers onto. This means I will either have to fabricate an extra plate which bolts onto the axle with holes for the calipers or replace the a stub axle with one with "ears". This image above shhows what it looks like today.
This image below is a bolt on adapter plates for converting a VW Beetle from drums to discs.
Similar plates could be fabricated and bolted on between the rear axle (16) and the stub axle (3). another idea is to change the stub axle to one from a car with rear disc brakes with mouting holes for the break calipers. This would probably mean also changing the wheel hub and bearing. Have a look at the next image with a stub axle from a VW Golf III with rear disc brakes. Notice the mouting holes for the brake calipers in the botton of the image. The stub axle doesn't look at all the same as the one for the A2 so I guess it will involve changing a lot of other stuff as well.
Well, the search for the best solution for changing the brakes goes on...

October 20, 2012

Converting an Audi A2 to electric

Ever since I bought my last car I've said "My next car will be an electric". But, I've never found an electric car that suits my budget and my other needs of a car. It has to be able to transport me and my family, which is three humans and two dogs, 60 km everyday to and from work.
So, instead I'm planning to convert a 2004 Audi A2 to electric.
I have been studying EV conversions since before summer and trying to figure out how to do it. I guess I'm not all there, but some things are getting clearer.
First, a donor car. I have decided to convert a 2004 Audi A2. Its a small, but roomy car that Audi manufactured between 1999 and 2005. It will just about house the family. It is small and light, mainly because it is built from aluminium which means that it will not rust so bad.
I just bought the car last week and here is a picture of it.

Maybe I'll paint it when it's finished so it will look prettier.